Polaris 2012 RANGER RZR 570 INTL, 2012 RANGER RZR 570 Service Manual

2012 RANGER RZR 570 / INTL

SERVICE MANUAL

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at

www.polarisdealers.com.

This Service Manual is designed primarily for use by equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some pro cedures ou tlined i n th is man ual re quire a sou nd kn owledge of me chanical t heory, to ol use, and sho p proc

edures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you ha ve any doubt as to yo ur ability to perform any of th e procedures outlined in th is Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful. Plea

se provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Publications Question'.

Consumers, please provide your feedback in writing to: Polaris Indu 2100 Hwy 55, Medina, MN 55340.

Publication Printed November 2011 (PN 9923523) Rev. 3

© Copyright 2011 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Dep ictions an d/or p rocedures in t his pu blication are int ended for re ference use only. N o liability can be accept ed for omissions or inaccura cies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

certified Polaris Master Service Dealer technicians in a p roperly

stries Inc. ATTN: Service Publications Department,

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

WARNING

CAUTION

Throughout this manual, important information is brought to your attention by the following symbols:

SAFETY ALER T WARNING ind icates a po tential h azard that ma bystander or person(s) inspecting or servicing the vehicle.

SAFETY ALER T CAUTION indicates a potential h vehicle.

CAUTION indicates special p

NOTE provides key information by clarifying

IMPORTANT provides key reminders during disassembly

recautions that must be taken to avoid vehicle damage or property damage.

instructions.

azard tha t may r esult in min or personal in jury or damage to th e

NOTE:

IMPORTANT:

, assembly and inspection of components.

y result in se vere injury or dea th to the o perator,

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of

Torx, Registered Trademark of Textron

Hilliard, Trademark of the H

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Pola ris factor y pu blications can be do wnload www.purepolaris.com or by contacting the nearest Polaris dealer.

illiard Corporation

Neward Enterprises, Inc.

ed fro m www.polarisindustries.com, pu rchased fr om

GENERAL INFORMATION

MAINTENANCE

ENGINE / COOLING SYSTEM

ELECTRONIC FUEL INJECTION

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . .

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

2012 RANGER RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

2012 RANGER RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

2012 RANGER RZR 570 INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

2012 RANGER RZR 570 INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

. . . . . . . . . . . . . . . . . . . . . 1.2

1.1

9923523 - 2012 RANGER RZR 570 Service Manual

GENERAL INFORMATION

}

Machine Model Number Identification

}

Model Year Designation

Basic Chassis 

Designation

Engine Designation

Emissions &  Model Option

R 1 2 V H 5 7 A D

}

4 X A V H 5 7 A * B P 0 0 0 0 0 0

}

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

World

Mfg. ID

Engine

Vehicle Description

Vehicle Identifier

Check Digit

Model

Year

Body Style

Plant No.

Individual Serial No.

* This could be either

a number or a letter

Powertrain

Emissions

Figure 1-1

Engine Serial

Figure 1-2

Number

MODEL INFORMATION

Model Identification

The machine model number must be used with any correspondence regarding warranty or service.

Engine Designation Number

1204286..............................................................................Single Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start

VIN Identification

Vehicle and Engine Serial Number Lo

Whenever corresponding about a Polaris ORV, refer to the ve hicle identification number (VIN) and the engine serial number.

The VIN can be found stamped on a portion of the left-han (see Figure 1-1)

The engine model and serial number can be found on a decal applied to the crankcase on the front of the engine.  (see Figure 1-2)

1.2

cation

d rear upper frame rail, above the left rear wheel. 

9923523 - 2012 RANGER RZR 570 Service Manual

VEHICLE INFORMATION

Key Series Number

KEY COVER P/N 5533534

Publication Numbers

Model Model No. Owner’s Manual Parts Manual

GENERAL INFORMATION

2012 RANGER RZR

2012 RANGER RZR 570 INTL. R12VH57FX 9923521 9924058

NOTE: When ordering service parts be sure to use the correct parts manual.

NOTE: Polaris fa ctory pu blications c an be fo und a www.purepolaris.com.

570 R12VH57AD 9923521 9923522

t www.pola risindustries.com or p urchased f rom

Replacement Keys

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

Series# Part Number

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar to ol, if ava ilable. Polaris r ecommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at

http://polaris.spx.com/.

1.3

9923523 - 2012 RANGER RZR 570 Service Manual

GENERAL INFORMATION

GENERAL SPECIFICATIONS

MODEL: 2012 RANGER RZR 570

MODEL NUMBER: R12VH57AD ENGINE NUMBER: 1204286

Category Dimension / Capacity

Length 107.5 in. / 273.05 cm

Width 50 in. / 127 cm

Height 69 in. / 175.26 cm

Wheel Base 77 in. / 196 cm

Ground Clearance 10 in. / 25.4 cm

Dry Weight 970 lbs. / 440 kg

Front Storage Capacity

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Ca

pacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

20 x 40 x 9" (51 x 102 x 23 cm)

(Inclu

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg des rider(s), cargo, accessories and trailer tongue weight)

1.4

9923523 - 2012 RANGER RZR 570 Service Manual

GENERAL INFORMATION

MODEL: 2012 RANGER RZR 570

MODEL NUMBER: R12VH57AD ENGINE NUMBER: 1204286

Engine

Platform

Engine Number 1204286

Engine Displacement 567cc

Number of Cylinders 1

Bore & Stroke (mm) 99 x 73.6 mm

Compression Ratio 10:1

Compression Pressure 80 - 120 psi (decompression)

Engine Idle Speed 1200 ± 100 RPM

Engine Max Operating RPM 7750 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Plus Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 l)

Overheat Warning Instrument Cluster Indicator

Exhaust System

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 43-48 psi (296.5 - 331 KPA)

Fuel Filters In tank, See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 650 Watts @ 7000 RPM

Headlights 2 - Halogen: Single Beam 55W

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

Starting System Electric Start

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) ECU Controlled

Spark plug / Gap

Battery (RZR)

Instrument Type Multifunction Instrument Cluster

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid

oled, 4-Stroke, DOHC

Single Headpipe / Single Silencer

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

RG4YCX / .0276” - .0315”

.7 - .8 mm)

(

Yuasa YB14-B2 /

14 Amp

EFI / Chassis / Fan / Fuel Pump /

Drive / Fuel Pump: 10 Amp

ghts / EFI / Accessory: 20 Amp

Hr. / 12 Volt

Hea

EFI: 30 Amp

sis: 30 Amp

Chas

dlight

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.818:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Belt 3211143

Steering / Suspension

Front Suspension

Front Travel 9 in. / 23 cm

Rear Suspension

Rear Travel 9.5 in. / 24 cm

Shock Preload Adjustment

Front / Rear

Toe Out

Wheels / Brakes

Front Wheel Size

Front Tire Type / Size

Rear Wheel Size

Rear Tire Type / Size

Tire Pressure

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml)

Polaris AGL Plus

44 oz. (1300 ml)

Independent Dual A-arm

w/Anti-Sway Bar

Independent Dual A-arm

w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4 in. (3 - 6.4 mm)

12 x 6 / Steel

Ancla / 25 x 8 R12

12 x 8 / Steel

Ancla / 25 x 10 R12

Front: 10 psi (69 kPa)

Rear: 12 psi (83 kPa)

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Shift

ight

25-52

632409)

25-48

(5632408)

Meters

(Feet

Altitude

)

0-1500

(0-5000)

1500-3700

(50

00 - 12000)

Drive

Spring

Black

(7043594)

Black

(7043594)

1.5

9923523 - 2012 RANGER RZR 570 Service Manual

GENERAL INFORMATION

MODEL: 2012 RANGER RZR 570 INTL

MODEL NUMBER: R12VH57FX ENGINE NUMBER: 1204286

Category Dimension / Capacity

Length 107.5 in. / 273.05 cm

Width 50 in. / 127 cm

Height 69 in. / 175.26 cm

Wheel Base 77 in. / 196 cm

Ground Clearance 10 in. / 25.4 cm

Dry Weight 1001 lbs. / 454 kg

Front Storage Ca

pacity

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight

pacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

20 x 40 x 9" (51 x 102 x 23 cm)

ncludes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

1.6

9923523 - 2012 RANGER RZR 570 Service Manual

GENERAL INFORMATION

MODEL: 2012 RANGER RZR 570 INTL

MODEL NUMBER: R12VH57FX ENGINE NUMBER: 1204286

Engine

Platform

Engine Number 1204286

Engine Displacement 567cc

Number of Cylinders 1

Bore & Stroke (mm) 99 x 73.6 mm

Compression Ratio 10:1

Compression Pressure 80 - 120 psi (decompression)

Engine Idle Speed 1200 ± 100 RPM

Engine Max Operating RPM 7750 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Plus Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 l)

Overheat Warning Instrument Cluster Indicator

Exhaust System

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 43-48 psi (296.5 - 331 KPA)

Fuel Filters In tank, See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 650 Watts @ 7000 RPM

Headlights (INTL) 2 - Halogen: 55W Low / 60W High

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

INTL Features

Starting System Electric Start

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) ECU Controlled

Spark plug / Gap

Battery (RZR)

Instrument Type Multifunction Instrument Cluster

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid

oled, 4-Stroke, DOHC

Single Headpipe / Single Silencer

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

Turn Signals, Rear Diff. Control,

rn, Lic. Plate Light

RG4YCX / .0276” - .0315”

.7 - .8 mm)

(

Yuasa YB14-B2 /

14 Amp

EFI / Chassis / Fan / Fuel Pump /

Drive / Fuel Pump: 10 Amp

ghts / EFI / Accessory: 20 Amp

Hr. / 12 Volt

Hea

EFI: 30 Amp

sis: 30 Amp

Chas

dlight

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.818:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Belt 3211143

Steering / Suspension

Front Suspension

Front Travel 9 in. / 23 cm

Rear Suspension

Rear Travel 9.5 in. / 24 cm

Shock Preload Adjustment

Front / Rear

Toe Out

Wheels / Brakes

Front Wheel Size

Front Tire Type / Size

Rear Wheel Size

Rear Tire Type / Size

Tire Pressure

Brake - Front / Rear

Brake Fluid DOT 4

Parking Brake Equipped

Polaris Demand Drive Plus

6.75 oz. (200 ml)

Polaris AGL Plus

44 oz. (1300 ml)

570 INTL: 41 oz. (1200 ml)

Independent Dual A-arm

w/Anti-Sway Bar

Independent Dual A-arm

w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4 in. (3 - 6.4 mm)

12 x 6 Aluminum

Ancla / 25 x 8 R12

12 x 8 Aluminum

Ancla / 25 x 10 R12

Front: 10 psi (69 kPa)

Rear: 12 psi (83 kPa)

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Shift

ight

25-52

632409)

25-48

(5632408)

Meters

(Feet

Altitude

)

0-1500

(0-5000)

1500-3700

(50

00 - 12000)

Drive

Spring

Black

(7043594)

Black

(7043594)

1.7

9923523 - 2012 RANGER RZR 570 Service Manual

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

°C to °F:

9/5

1.8

(°C + 32) = °F °F to °C:

9923523 - 2012 RANGER RZR 570 Service Manual

5/9

(°F - 32) = °C

Standard Bolt Torque Specification

Grade 2

Grade 5

Grade 8

GENERAL INFORMATION

Bolt Size

1/4-20 5 (7) 8 (11) 12 (16)

1/4-28 6 (8) 10 (14) 14 (19)

5/16-18 11 ( 1 5 ) 17 (23) 25 (35)

5/16-24 12 (16) 19 (26) 29 (40)

3/8-16 20 (27) 30 (40) 45 (62)

3/8-24 23 (32) 35 (48) 50 (69)

7/16-14 30 (40) 50 (69) 70 (97)

7/16-20 35 (48) 55 (76) 80 (110)

1/2-13 50 (69) 75 (104) 110 (152)

1/2-20 55 (76) 90 (124) 120 (166)

Grade 2

. Lbs. (Nm)

Grade 5

Ft. Lbs. (Nm)

Grade 8

Ft. Lbs. (Nm)

Metric Bolt Torque Specification

Grade

Bolt Size

M3 .3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

M4 .8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

M5 1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

M6 3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

M8 7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

M10 14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

M12 26 (35) 33 (45) 63 (85) 97 (130) 11 ( 1 5 0 )

M14 37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

M16 59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

M18 81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

4.6 4.8 8.8 / 8.9 10.9 12.9

Ft. Lbs. (Nm) Dry Threads

9923523 - 2012 RANGER RZR 570 Service Manual

1.9

GENERAL INFORMATION

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

1.10

9923523 - 2012 RANGER RZR 570 Service Manual

MAINTENANCE

CHAPTER 2

MAINTENANCE

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

50 - 500 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

FUEL PUMP / FUEL FILTERS . . . . . . .

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

ENGINE AND PVT INTAKE PRE-FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

ENGINE BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

ENGINE AND TRANSMISSION MOUNTS. . . . . . . . . . . .

COMPRESSION TEST SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

TRANSMISSION AND FRONT GEARCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

SPECIFICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . .

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . .

FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

. . . . . . . . . . . . . . . . . . . . . . . 2.18

. . . . . . . . . . . . . . . . . . . . . . . . 2.23

. . . . . . . . . . . . . . . . . . . . . . . . 2.27

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.1

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

WHEEL TOE ALIGNMENT INSPECTION

WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

PARKING BRAKE CABLE ADJUSTMENT (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

PARKING BRAKE PAD INSPECTION (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

SPECIAL TOOLS

SPX Corporation: 1-800-328-6657 or on-line at http://polaris.spx.com/.

2.2

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

WARNING

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts a s necessar parts, use genuine Pure Polaris parts available from your Polaris dealer.

NOTE: Service a nd ad justments are critic al. If y ou’re no procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon aver approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in m

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold we

Pay special attention to the oil level. A oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

ather operation

ud, water or sand

rise in oil level during cold weather can indicate contaminants collecting in the

y. When inspection reveals the need for replacement

t fa miliar w ith sa fe s ervice a nd adjustment

age riding conditions and an average vehicle speed of

Break-In Period

The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

• Drive vehicle slowly at first while varying the thr

• Pull only light loads.

• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.

• Change both the engine oil and filter after 25 hours or one month.

• See “Owner’s Manual” for additional break-in information.

ottle position. Do not operate at sustained idle.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

 = CAUTION: Due to the nature of these adjustments, it is recommended this service be p erformed by a n

authorized Polaris dealer.

 = SEVERE USE ITEM: See information provided above.

E = Emission

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

Improperly performing the procedures marked could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Control System Service (California).

2.3

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Pre-Ride - 25 Hour Maintenance Interval

Maintenance Interval

Item

Hours Calendar

 Steering - Pre-Ride -

Front Suspension - Pre-Ride -



Rear Suspension - Pre-Ride -



Tires - Pre-Ride -

Brake Fluid Level - Pre-Ride -



Brake Pedal Travel - Pre-Ride -



Brake Systems - Pre-Ride -

Wheels / Fasteners - Pre-Ride -

Frame Fasteners - Pre-Ride -



Engine Oil Level - Pre-Ride -

(whichever comes first)

Miles

Remarks

(KM)

Make adjustments as needed.  See Pre-Ride Checklist on Page 2.10.



Air Filter - Pre-Ride - Inspect; replace as needed

Coolant Level - Daily -

Head Lamp / Tail Lamp - Daily -



Air Filter - Weekly - Inspect; replace as needed



Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically



Brake Pad Wear / Inspect



Parking Brake



Parking Brake Cable



Adjustment (INT’L)



Battery 25 H Monthly 250 (400) Check terminals; clean; test

Front Gearcase Oil 



(Demand Drive Plus)

Transmission - Main



(AGL Gearcase Lubricant)

EEngine Oil Change 

(Break-In Period)

Pads (INT’L)

10 H Monthly 100 (160) Inspect periodically

25 H - - Inspect; adjust tension after first 25 hours

25 H Monthly 250 (400) Inspect level; change yearly

25 H 1 M 250 (400) Perform a break-in oil change at one month

Check level daily, change coolant every 2

ars

Check operation; apply die replacing

lectric grease if



Perform these procedures more often for vehicles subjected to severe use.

E Emis 

sion Control System Service (California)

Have an authorized Polaris dealer perform these services.

2.4

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

50 - 500 Hour Maintenance Interval

Maintenance Interval

(whichever comes first)

Item



Throttle Cable / Throttle Pedal 50 H 6 M 300 (500) Inspect; adjust; lubricate; replace if necessary

Throttle Body Air Intake Ducts

 General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.

 Steering 50 H 6 M 500 (800) Lubricate

 Front Suspension 50 H 6 M 500 (800) Lubricate

 Rear Suspension 50 H 6 M 500 (800) Lubricate







 Radiator / Cooling Hoses 100 H 12 M 1000 (1600) Inspect; clean external surfaces

 Engine Assembly Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification

 Wiring 100 H 12 M 1000 (1600)

 Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

 Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

 Shocks 100 H - - Visually inspect shock seals

 Brake Fluid 200 H 24 M

 



 Toe Adjustment -

nge

/ Fla

Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust

Cooling System 50 H 6 M 500 (800)

Fuel System 100 H 12 M 600 (1000)

Spark Plug 100 H 12 M 600 (1000) Inspect; replace as needed

Engine Oil & Filter Change 100 H 6 M 1000 (1600)

Parking Brake Cable Adjustment (INT’L)

Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed

Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect

Spark Arrestor 300 H 36 M 3000 (4800) Clean out

Shocks 500 H 12 M - Change shock oil and seals

Valve Clearance Check 500 H - 5000 (8050) Inspect / Adjust as needed

Headlight Aim - Adjust as needed

Hours Calendar

50 H 6 M 300 (500) Inspect ducts for proper sealing / air leaks

100 H 6 M 1000 (1600) Inspect; adjust tension as needed

Miles

)

(KM

Inspect coolant strength seasonally; pressure

stem yearly

test sy

Check for leaks at fill cap, fuel line / rail, and fuel

Replace lines every two years.

pump.

Perform a break-in oil change at 25 hours or one

nth / always replace oil filter when changing

engine oil

Inspect for wear, routing, security; apply

ectric grease to connectors subjected to

diel water, mud, etc.

2000 (3200) Change every two years (DOT 4)

Inspect periodically; adjust when parts are

eplaced

Remarks

 Perform these procedures more often for vehicles subjected to severe use.

E Emission Control Sys

Have an authorized Polaris dealer perform these services.



tem Service (California)

2.5

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

Change after 1st month or first

hours of operation, 100 hours

25 thereafter; Change more often (25 hours) in severe duty conditions or short trip cold weather operation

1 Engine Oil

Polaris PS-4 Plus Per

formance Synthetic 

4-Cycle Engine Oil

Add oil to proper level on

stick

dip

2 Engine Coolant Polaris 60/40 Coolant

3 Brake Fluid Polaris DOT 4 Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

Maintain coolant level in

olant reservoir bottle

Maintain fluid level between “MAX an master cylinder reservoir

d “MIN” lines on the

Check level daily, change coolant every 2 years

Check level during pre-ride inspection; change fluid every two years

2.6

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

4 Front Gearcase Polaris Demand Drive Plus

5 Transmission

* More often under severe use, such as operated in water or under severe loads.

Polaris AGL Plus Gearcase Lubricant

Add lubricant until it is visible at the fill

hole threads

Check level every 25 hours; change fluid yearly

Check level every 25 hours; change lubricant yearly

2.7

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Rear Stabilizer Bar

Prop Shaft

Front Suspension

Rear Suspension

Front Stabilizer Bar

Grease Lubrication Points

There are grease fittings at each A-arms pivot point, each front or rear stabilizer bushing, and on the front propshaft yoke. Apply grease until all traces of water have been purged out at each of these areas.

Item Recommended Lube Method Frequency

Front Propshaft Yoke(s)

A-arm Pivot Bushings

Stabilizer Bar Bushings

Polaris Premium U-Joint Grease

Grease fittings every 500 mi

les (800 km).

Grease before long periods o

f storage, and after thoroughly washing or submerging the vehicle.

2.8

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2876244

2876245

2878068

2878069

2878070

2877922

PS-4 Plus Synthetic 4-Cycle Engine Oil

uart)

PS-4 Plus Synthetic 4-Cycle Engine Oil

Gallon)

(

Gearcase / Transmission Lubricants

AGL Plus Gearcase Lubricant (1 Qt.) (12 Count)

AGL Plus Gearcase Lubricant (1 Gal.) (4 Count)

AGL Plus Gearcase Lubricant (2.5 Gal.) (2 Count)

Demand Drive Plus  (Quart)

NOTE: Each item c an b e pu rchased se parately at your local Polaris dealer.

Part No. Description

Additives / Sealants / Thread Locking Agents / Misc.

2871950

2871326

2870652 Fuel Stabilizer (16 oz.) (12 count)

2872189 DOT 4 Brake Fluid (12 count)

2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)

NOTE: The nu mber co unt indicated by each part number units that are shipped with each order.

Loctite™ Threadlock 242  (6 ml.) (12 count)

Premium Carbon Clean  (12 oz.) (12 count)

in th e t able above ind icates t he numbe r of

2877923

2870465 Oil Pump for 1 Gallon Jug

2871312 Grease Gun Kit

2871322

2871423

2871460 Starter Drive Grease (12 Count)

2871515 Premium U-Joint Lube (3 oz.) (24 Count)

2871551 Premium U-Joint Lube (14 oz.) (10 Count)

2871329 Dielectric Grease (Nyogel™)

2871323 60/40 Coolant (Gallon) (6 Count)

2871534 60/40 Coolant (Quart) (12 Count)

Demand Drive Plus (2.5 Gallon)

Grease / Specialized Lubricants

Premium All Season Grease  (3 oz. cartridge) (24 Count)

Premium All Season Grease  (14 oz. cartridge) (10 Count)

Coolant

2.9

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Shift Cable

Mount

Dust Boot

Clevis Pin

Shift Cable

Jam Nut (A)

Jam Nut (B)

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check condition and pressures

• Fuel tank - fill to proper

• All brakes - check operation and adjustment

• Throttle - check for free operation and closing

• Headlights/Taillights/Brakelights - also check ope

ration of all indicator lights and switches

• Ignition switch - check for proper function

• Wheels - check for tightness of wheel nuts and axle

nuts; check to be sure axle nuts are secured

by cotter pins

• Air cleaner element - check for dirt; replace if necessar

• Steering - check for free operation noting any unu

sual looseness in any area

level

Shift Cable Inspection / Adjustment

Shift c able a djustment m ay be ne cessary if sy mptoms include:

• No AWD or gear position display on instrument er

clust

• Ratcheting noise on deceleration

• Inability to engage into a

• Excessive gear clash (noise)

• Gear selector moving out of desired range

1. Locate th e shift ca ble in th e r ear r ight-hand whe el w

ell area.

gear

• Loose parts - visually inspect vehicle for any dam

aged or loose nuts, bolts or fasteners

• Engine coolant - check for proper level at the re

covery bottle

• Check all front and rear suspension components

r wear or damage.

Frame, Nuts, Bolts, and Fasteners

Periodically inspect the tor que of all fasten ers in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

2. Inspect shift cable, clevis pin, pivot bushings, and dust t. Replace if worn or damaged.

boo

3. If adjustment is required: Lo

cable out of the mount and rotate jam nut (B).

osen jam nut (A), pull the

2.10

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

WARNING

Fuel Line

4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) gear and PARK (P).

5. Thread jam nut (A) or (B) as required to obtain proper

ble adjustment.

NOTE: This procedure may require a few attempts to

tain the proper adjustment.

6. Once the p roper ad justment is obtained, place the

cable and jam nut (B) into the mount. Tighten jam

shift nut (A) against the mount.

7. Start engine and shift through all gears to ensure the

cable is properly adjusted. If transmission still

shift ratchets after cable adjustment, the transmission will require service.

FUEL SYSTEM AND AIR INTAKE

Fuel System

Fuel Line

1. Check the quick-connect fu el line from th e en gine fuel rail conn ection to th e fu el ta nk connection for signs of wear, de terioration, da mage or leakag e. Replace if necessary.

2. Be sure fuel line is routed and retained properly.

IMPORTANT: Make sure line is not kinked or pinched.

Gasoline is extremely flammable and explosive

under certain conditions.

Always stop the engine and refuel outdoors or in

a well ventilated area.

Do not smoke or allow open flames or sparks in

r near the area where refueling is performed or

where gasoline is stored. Do not overfill the tank. Do not fill the tank If you get gasoline in your eyes or if you swallow

soline, seek medical attention immediately.

If you spill gasoline on y immediately wash it off with soap and water

and change clothing.

Never start the engine or let it run in an enclosed

ea. Engine exhaust fumes are poisonous and

can result in loss of consciousness or

death in a short time.

Never drain the fuel when the engine is hot.

Severe burns

our skin or clothing,

may result.

neck.

3. Replace fuel line every two years.

2.11

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Fuel Pump Asm

Fuel Line

Throttle Pedal

Fuel Pump / Fuel Filters

The RZR 57 0 e ngine u ses a se rviceable, hi gh-volume, high-pressure, fuel pump that includes a preliminary filter and a n in ternal fine filter located be fore th e p ump regulator.

NOTE: Neither f ilter is se rvicable individua lly. Mu st

place the fuel pump as an assembly.

Vent Lines

1. Check fuel tan k, fr ont gearcase an d transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

2. Be sure vent lines are routed and secured properly.

IMPORTANT: Ensure lines are not kinked or pinched.

Throttle Pedal Inspection

If the throttle pedal has excessive play due to cable stretch or cab le misadju stment, it wil l cause a dela y in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic.

NOTE: Refer to Chapter 4 for fuel pump replacement a

nd all other information related to the EFI System.

2.12

9923523 - RANGER RZR 570 Service Manual

Check the throttle pedal play periodically in accor dance with the Per necessary.

iodic Maintenance Chart and adjust the play if

MAINTENANCE

Throttle Body

Boot

Press In Tabs

Pre-filter Cover

Pre-Filters

Throttle Freeplay Adjustment

Inspection

1. Place the transmission in the P (Park) position.

2. Start the engine, and warm it up thoroughly.

3. Measure the distance the throttle pedal moves before en gine be gins to increase in RPM . Freeplay

the should be 1/16” - 1/8” (1.5 - 3 mm).

Adjustment

1. Remove the cargo box access panel to ac

throttle body area.

cess the

4. Re-tighten the jam nut after fina

5. Apply a small am ount of grease to the inside of the ot and slide it over the cable adjuster to its original

bo position.

6. Reinstall the cargo box access panel.

l adjustment is made.

Engine and PVT Intake Pre-Filter Service

It is r ecommended that the e ngine and PVT intake prefilter b e in spected daily. T he filter sho uld be inspe cted using the following procedure:

NOTE: T just above the left-rear wheel fender.

1. Press “IN” on the intak e grill cover

he engine and PVT inta ke pr e-filter is locate d

tabs and remove

the pre-filter cover to access the pre-filters.

2. Locate thro ttle ca ble o n the le ft-hand side o f the

3. Using an o pen-end wrench, lo osen the a djustment

NOTE: While adj usting, li ght pedal in and out.

thr

ottle body. Slide back the cable adjuster boot.

m nut (A). Using another open-end wrench, move

ja the cable adjuster (B) until 1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved at the throttle pedal.

ly move th e t hrottle

2. Remove and insp ect the p re-filters. If ne cessary,

an with soapy water and dry with compressed air.

cle

3. Reinstall the dry pre-filter s an

cover.

d inst all the pr e-filter

2.13

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Remove Hose

Install Hose

Air Filter Service

It is recommended that the air filter be inspected as part of pre-ride inspection. In extremely dusty conditions, air filter replacement will be required more often.

The filter shou ld be inspected procedure:

using the following

4. Inspect the air filter element and replace if necessary. not attempt to clean the air filter.

NOTE: If the filter has been soaked with fuel or oil it

st be replaced.

NOTE: Service more frequently if vehicle is operated in wet extended periods.

Installation

1. Clean the air box and air box cover thoroughly.

2. Place the filter into the air box with the air filter pleats

cond itions o r at hig h th rottle ope ration f or

cing UP, as shown.

Removal

NOTE: Th

access panel.

1. Thoroughly clean the air box area to remove dirt and

2. Loosen hose clamp (A) and remove the intake hose

3. Unlatch the (6) clips and carefully remove the air box

e air box is located underneath the cargo box

ebris.

m the air box cover.

fro

cover. Be sure not air filter element during removal.

to let the air box cover contact the

3. Carefully install air box cover and secure with the (6)

lips.

4. Reinstall the clea n intake h ose a nd tigh ten ho se

lamp (A).

5. Reinstall the cargo box access cover.

2.14

9923523 - RANGER RZR 570 Service Manual

Air Box / Air Filter Exploded View

Clip (6)

Boot

Air Intake Duct

Air Intake

Air Filter

Clamps

Clamp

Air Box Cover

Box

Grommets

Mount

Drain

Clamp

Engine Pre-filter

PVT Pre-filter

Intake Baffle Box

Remove Hose From Air Box

Cover for Filter Removal

MAINTENANCE

9923523 - RANGER RZR 570 Service Manual

2.15

MAINTENANCE

WARNING

Maintain Oil Level In SAFE Range

DO NOT Overfill the Engine

ENGINE

Engine Oil Level

This single cylinder engine is a wet-sump engine, meaning the o il is co ntained in t he bo ttom of th e cr ankcase. To check the oil level follow the procedure listed below:

IMPORTANT: Thoroughly clean engine around the oil

ain plug, oil filte r and oil dip stick to prevent

dr contamination from entering the engine.

1. Position vehicle on a level surface.

2. Place the transmission in Park (P).

3. Be sure engine OFF has not been run for at lease 3 utes.

min

IMPORTANT: Do not run the machine and then immediat

4. Locate the engine oil dipstick:

ely check the oil level.

• RZR 57 engine case; accessible through the righthand rear wheel well area.

0 - Located on the right-hand side of the

8. Unscrew and remove dipstick and verify the oil level is

in the SAFE (XX) range. Add oil as indicated by the level on the dips tick. D o not overfill (see N OTE below!).

NOTE: A rising oil level bet ween ch ecks in cool

ther driving can indicate contaminants suc h as

wea gas or moisture collecting in the crankcase. If the oil level is ov er t he f ull mar k, cha nge t he o il immediately.

9. Reinstall the dipstick and hand tighten.

Engine Oil and Filter Service

Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.

5. Thoroughly clean the engine around dipstick area.

6. Unscrew / remove dipstick and wipe dry with a clean cloth.

7. Reinstall the dipstick completely.

NOTE: Make certain the dipstick is thr eaded all the

into the engine case.

way

IMPORTANT: Thoroughly clean engine around the oil drain plug, oil f contamination from entering the engine.

Personal injury can occur when handling used

oil. Hot oil can cause burns or skin damage.

PS-4 Plus Synthetic 4-Cycle Engine Oil

1. Position vehicle on a level surface.

2. Place the transmission in PARK (P).

ilter an d oil dipst ick t o prev ent

Recommended Engine Oil:

(

PN 2876244) (Quart)

2.16

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MAINTENANCE

CAUTION

Drain Plug

NOTE: Drain plug is accessed through the skid plate.

Oil Filter

= T

3. If needed, start the engine and allow it to idle for three minutes until warm. Stop the engine.

4. Place a d rain pa n b eneath e ngine cr ankcase a nd

emove the drain plug.

Oil may be hot. Do not allow hot oil to come into

contact with skin, as serious burns may result.

5. Allow oil to drain completely.

6. Replace sealing washer on drain plug.

NOTE: The sealing surface on the drain plug should be

clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 1

8. Place a drain pan under vehicle below the oil filter.

9. Place sho p towels beneath oil filter. U Wrench (PU-50105) and a 3/8” extension, turn the oil filter counter-clockwise to remove it.

2 ft. lbs. (16 Nm).

sing Oil Filter

11. Lubricate O-ring on n ew filter with a film o f fre sh gine oil. Check to make sure the O-ring is in good

en condition.

12. Install new filter an d tur n by hand u ntil filter gasket

ntacts the sealing surface, then turn an additional

co 1/2 turn.

13. Remove the engine o il dipstick (see “Eng ine Oil vel”).

14. Using a long funnel, fill the sump with 2 qts. (1.9 l) of

4 Plus Synthetic Engine Oil (2876244).

PS-

Crankcase Drain Plug Torque:

12 ft. lbs. (16 Nm)

Oil Filter Torque:

Turn by hand until filter gasket contacts sealing

surface, then turn an additional 1/2 turn

Oil Filter Wrench:

PU-50105: 2.5” (64 mm)

15. Verify the transmission is still

16. Start the engine and let it idle for two minutes.

17. Stop the engine and inspect for leaks.

18. Re-check the oil level on the dipstick and add oil as

ecessary to bring the level to the upper mark on the

dipstick.

19. Dispose of used oil and oil filter properly.

positioned in PARK (P).

10. Using a clean dry cloth, clean filter sealing surface on the crankcase.

2.17

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MAINTENANCE

Breather

Hose

Engine Breather Hose Inspection

The engine is equipped with a breather hose. Inspect the breather hose fo r po ssible kinks or we ar. The hose is form fitted for a proper fit. Follow the breather hose from the engine crankcase to the a ir intake baffle box on the left-hand rear fender panel.

NOTE: Make sure line is not kinked or pinched.

Valve Clearance Inspection

IMPORTANT: Valve cl earance i nspection should be performed on a cold engine, at room temperature.

1. Remove the seats and disconn ect th e ne gative ( -) y cable. 

batter

2. Remove the cargo box access panel.

3. Remove the spar k plug wire from the en gine an d

ove the spark plug. Place a clean shop towel into

rem the spark plug tube to prevent debris from entering the combustion chamber.

4. Remove the (3) T40 bolts retaining the valve cover.

5. Remove the valve cover from the engine out of the

t-hand rear wheel well area.

righ

Engine and Transmission Mounts

Periodically inspect engine and transmission mounts for cracks or damage.

Refer to Chapter 3 “Engine Assembly mounting fastener torque values.

and Installation” for

Compression Test Specification

NOTE: This en gine does ha ve decompression components.

A smooth idle generally indicates engine compression is rarely a factor in running condition problems above idle speed.

Cylinder Compression:

80 - 120 psi (decompression)

good compression. Low

6. Remove the outer PVT cover and drive belt as shown

in ch

apter 6.

2.18

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MAINTENANCE

7. Rotate th e drive clu tch co unter-clockwise until the cam chain sprocket timing marks are aligned with the gasket sur face as sho wn (see Ch apter 3 for mo re TDC setting procedures).

IMPORTANT: Intake ca m s procket sh ould ha ve “I”

mar cam spr ocket shou ld hav e “E” ma rks aligned with gasket surface.

8. Measure th e valve clearance of each valve using

aligned with ga sket surface a nd the ex haust

Image for Reference Only

thickness (feeler) gauge. Record the measurement if clearance is out of specification.

9. If the valve clearance is out o to “Valve Clearance Adjustment” (see Chapter 3).

f specification, proceed

= In. / mm.

Intake Valve Clearance (cold):

.005-.007 in. (0.125-0.175 mm)

= In. / mm.

Exhaust Valve Clearance (cold):

.008-.010 in. (0.152-0.254 mm)

10. Repeat steps 8- 9 u ntil all (4) valves h ave b een

spected.

11. Inspect the valve cover seal and replace if necessary.

12. Install the valve cover and spark plug as outlined in Chapter

13. Install d rive b elt an d o uter clu tch cover a nd ( 8) re

taining screws (see Chapter 6)

= T

Outer Clutch Cover Screws:

45-50 in. lbs. (5 Nm)

14. Connect the negative (-) battery cable to the battery.

15. Start the engine to ensure proper operation.

16. Reinstall the cargo box access panel and seats (see Chapter

5).

2.19

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MAINTENANCE

WARNING

40 in. lbs.

(4.5 Nm)

18 ft. lbs.

(24.5 Nm)

Gaskets and Seals -

Replace Each Time Component is Removed

18 ft. lbs.

(24.5 Nm)

Exhaust - Spark Arrestor

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust system

becomes very hot. Serious burns could result from

contact with the exhaust components. Allow

components to cool sufficiently before proceeding.

Wear eye protection and gloves.

Never run the engine in an enclosed area. Exhaust

ntains poisonous carbon monoxide gas that can

cause loss of consciousness or death in a very

short time.

Periodically clean spark arrestor to remove accumulated carbon.

1. Allow engine and exhaust system to completely cool.

2. Remove the retaining screw, washer and spark arrestor from the end of the silencer.

3. Use a non-synthetic brush to clean the arrestor screen.

4. Inspect the screen for wear and damage. Replace if needed.

5. Reinstall the arrestor and torque the screw to 40 i

n. lbs. (4.5 Nm).

2.20

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MAINTENANCE

= T

TRANSMISSION AND FRONT GEARCASE

Specification Chart

Gearcase Lubricant Capacity Fill / Drain Plug Torque

Transmission AGL Plus Gearcase Lubricant 44 oz. (1300 ml) 10-14 ft. lbs. (14-19 Nm)

Transmission (INTL) AGL Plus Gearcase Lubricant 41 oz. (1200 ml) 10-14 ft. lbs. (14-19 Nm)

Front Gearcase Demand Drive Plus 6.75 oz. (200 ml) 8-10 ft. lbs. (11-14 Nm)

Transmission Lubrication

NOTE: It is important to f ollow t he t ransmission maintenance inte rvals de scribed in the Periodic Maintenance Chart . Regular lu bricant leve l inspections should be performed as well.

The transmission lubricant level should be che cked and

nged in accordance with the maintenance schedule.

cha

• Be sur e ve hicle is po sitioned on a level su rface en checking or changing the lubricant.

• Check vent hose to be sure it

and unobstructed.

Transmission Lubricant Level Check

The fill plug is located on the rear portion of the transmission gearcase. Access the vehicle. Maintain lubricant level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug and check the lubricant level.

is routed properly

the fill plug at the rear of

3. If lubricant level is not even with the bottom threads, dd the r ecommended lubricant as needed. Do not

a overfill.

4. Reinstall the fill plug and torque

Fill / Drain Plug Torque:

10-14 ft. lbs. (14-19 Nm)

to specification.

2.21

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MAINTENANCE

= T

Transmission Lubricant Change

The drain plug is located on the gearcase. Access the drain plug through the drain hole in the skid plate.

1. Remove the fill plug (refer to “Transmission Level Check”).

2. Place a drain pan under the transmission drain plug.

3. Remove d rain p lug and allo w lub ricant to dr ain completely.

bottom of the transmission

Lubricant

6. Add the recommended amount of lubricant thro ugh the fill plug bottom of the fill plug hole w hen filling the transmission. Do not overfill.

Recommended Transmission Lubricant:

7. Reinstall fill plug with a ne

specification.

hole. Maintain the lubricant level at the

AGL Plus Gearcase Lubricant

(PN 2878068) (Quart)

Capacity: 44 oz. (1300 ml)

Capacity (INTL): 41 oz. (1200 ml)

w O-r ing a nd tor que to

Fill / Drain Plug Torque:

10-14 ft. lbs. (14-19 Nm)

4. Clean the drain plug magnetic surface.

5. Reinstall drain plug with a ne

specification.

w O-ring and torque to

8. Check for leaks. Dispose of used lubricant properly.

2.22

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MAINTENANCE

= T

Front Gearcase Lubrication

NOTE: It is important to fo llow the fro nt gea rcase maintenance inte rvals de scribed in the Periodic Maintenance Chart . Regular fluid leve l ins pections should be performed as well.

The fron t gearcase fluid le vel should be checked and

nged in accordance with the maintenance schedule.

cha

• Be sur e ve hicle is po sitioned on a level su rface en checking or changing the fluid.

• Check vent hose to be sure it

and unobstructed.

Front Gearcase Fluid Level Check

The fill plug is located on the bottom gearcase. Access the fill plug through the right front wheel well. Maintain fluid level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug and check the fluid level.

is routed properly

right side of the front

4. Reinstall the fill plug and torque to

Fill / Drain Plug Torque:

8-10 ft. lbs. (11-14 Nm)

Front Gearcase Fluid Change:

The d rain pl ug is locate d on th e bo ttom of th e fro nt

rcase. Access the drain plug through the access hole

gea in the frame underneath the front gearcase.

1. Remove the fill plug (refer to “Front Gearcase Fluid Level Chec

2. Place a drain pan under the front gearcase drain plug.

3. Remove th e dr ain plug and allo w fl uid to drain completely

k”).

specification.

3. If fluid level is not even with the bottom threads, add the recommended fluid

as needed. Do not overfill.

4. Clean the drain plug magnetic surface.

5. Reinstall drain plug with a new

specification.

9923523 - RANGER RZR 570 Service Manual

O-ring and torque to

2.23

MAINTENANCE

= T

6. Add the recommended amount of fluid through the fill hole. Maintain the fluid le vel ev en wit h t he b ottom threads of the fill plug hole.

Recommended Front Gearcase Fluid:

Polaris Demand Drive Plus

(PN 2877922) (Quart)

Capacity: 6.

7. Reinstall fill plug with a ne

specification.

Fill / Drain Plug Torque:

8-10 ft. lbs. (11-14 Nm)

8. Check for leaks. Dispose of used fluid properly.

75 oz. (200 ml)

w O- ring an d tor que to

2.24

9923523 - RANGER RZR 570 Service Manual

COOLING SYSTEM

Water Pump

Upper Engine Hose

Lower Engine

Hose

Bypass Hose

Radiator

Recovery

Bottle

Upper Radiator

Hose

Pressure Cap

Filler Neck

Hoses

Cooling Fan

Cooling System Exploded View

MAINTENANCE

2.25

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MAINTENANCE

Recovery Bottle

Pressure Cap

WARNING

Cooling System Overview

The engine coolant level is controlled, or maintained, by the recovery system. The re covery system components are the recovery bo ttle, radiator filler neck, radiator pressure cap and connecting hose.

As coola nt op erating tem perature in creases, the

xpanding ( heated) excess coola nt is for ced o ut of the

e radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

NOTE: Some coolant level drop on new machines is

rmal as the system is purging itself of trapped air.

no Observe coolan t lev els of ten during the brea k-in period.

NOTE: Overheating of engine could oc cur if air is

t fully purged from system.

Polaris Premium 60/40 is already premixed and ready to

e. Do not dilute with water.

Coolant Level Inspection

The pressure cap and recovery bottle are located under the front hood of the vehicle. The coolant level must be maintained be tween th e minimum and maximum levels indicated on the recovery bottle.

4. If the coolant level is below the MIN line, inspect the co

olant level in the radiator.

NOTE: If o verheating is e vident, allow system to cool comp radiator and inspe ct f or s igns of trapped a ir in system.

cause severe burns. The engine must be cool

5. Remove the pr essure ca p. Using a funnel, ad d

oolant to the top of the filler neck.

6. Reinstall the pressure cap.

NOTE: Use of a non-standard pressure cap will not allo

w the recovery system to function properly.

7. Remove recovery bottle cap and add coolant using a fu

8. Fill recov ery bottle to M AX premix Anti Freeze/Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

9. Reinstall the recovery bottle cap.

10. If co olant was re quired, sta rt eng ine an d check for leaks. Ma overheating.

letely and ch eck coolant leve l in th e

Never remove the pressure cap when the

engine is warm or hot. Escaping steam can

before removing the pressure cap.

nnel.

level w ith Polaris 60/40

ke su re radiator fins ar e clea n to pre vent

With the en gine at o perating temp level should be between the upper and lower marks on the coolant re covery bo ttle. If no t, per form the fo llowing procedure:

1. Position the vehicle on a level surface.

2. Remove the hood from the front cab.

3. View the coolant level in the recovery bottle.

erature, the coolant

2.26

Cooling System Pressure Test

Refer to Ch apter 3 fo r co oling sy stem pressure tes t procedure.

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

CAUTION

Antifreeze Hydrometer

WARNING

Drain Here

Coolant Strength / Type

Test th e str ength of the co olant u sing a n an tifreeze hydrometer.

• A 50/50 or 60/40 mixture of antifre water will provide the optimum c ooling, corrosion protection, and antifreeze protection.

• Do n ot use t ap water , stra ight a ntifreeze, or stra

ight water in th e system. T ap water co ntains minerals an d impu rities wh ich build up in the system.

• Straight water or antifree to freeze, corrode, or overheat.

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

ze may cause the system

eze and distilled

Coolant Drain / Fill

Coolant Drain

1. Remove the hood from the front cab.

Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool.

2. Slowly remove the pressure cap to relieve any cooling em pressure.

syst

3. Place a su itable drain pan underneath the rad iator

fitting on

4. Drain the coolant from the radiator by rem oving the

ower co olant ho se fro m the ra diator a s shown.

l Properly dispose of the coolant.

the front right-hand side of the vehicle.

Cooling System

1. Inspect all hoses fo r cracks, d eterioration, abrasion or leaks. Replace if necessary.

Do not over-tighten hose clamps at radiator,

or radiator fitting may distort, causing a

restriction to coolant flow.

Radiator hose clamp torque is 36 in. lbs. (4 Nm).

2. Check tightness of all hose clamps.

5. Allow coolant to completely drain.

6. Place a su itable d rain pan underneath t he lo wer ngine hose on the right-hand rear side of the vehicle.

2.27

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MAINTENANCE

= T

7. Remove the h ose and completely drain the engine. Reinstall the lower coolant hose.

8. Properly dispose of the coolant.

9. Remove the pressure cap. Using a funnel, add the recommended c fill the recovery bottle to the MAX level.

10. Refer to Chapter 3 for the “Cooling System Bleeding

ocedure”.

oolant to the top of the filler neck and

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

FINAL DRIVE / WHEEL AND TIRE

Wheel and Hub Torque Table

Wheel Nuts:

Steel Wheels: 27 ft. lbs. (37 Nm)

Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

Hub Retaining Nuts:

80 ft. lbs. (108 Nm)

NOTE: Do not lubricate the stud or the lug nut.

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the tra nsmission in PARK (P) and stop th e ine.

eng

3. Loosen the wheel nuts slightly. If wheel hub removal

equired, remove the cotter pin and loosen the hub

is r nut slightly.

4. Elevate the appropriate side of the vehicle by placing

suitable stand under the frame.

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is re quired, remove the hub nut and

shers.

2.28

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MAINTENANCE

CAUTION

Wheel Nuts (4)

Hub Nut

Use a new

cotter pin

Note

Tire Rotation

Val v e stem

facing outward

(RZR Only)

WARNING

Tread Depth 1/8" (3 mm)

Wheel Installation

1. Verify the transmission is still in PARK (P).

2. Install th e wh eel hub, washe rs, an d hub n ut, if reviously removed.

3. Place the wheel in the correct position on the wheel ub. Be sure the valve stem is toward the outside and

h rotation arrows on the t ire point towa rd fo rward rotation.

4. Attach the wheel nuts and finger tighten them.

5. Carefully lower the vehicle to the ground.

6. Torque the whee l nuts and/or hub nut to the proper

que specification listed in the tor que table at the

tor beginning of this section.

7. If hub nut was removed, install a ne

the hub nut has been tightened.

w cotter pin after

Tire Inspection

• Improper tire inflation may affect vehicle maneuverability.

• When replacing a tire always use original

uipment size and type.

• The use of non-standard size or type tires may

ffect vehicle handling.

Operating with worn tires will increase the

possibility of the vehicle skidding easily with

possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth

easures 1/8", (.3 cm) or less.

Tire Tread Depth

Replace tires when tread depth is worn to 1/8" (3 mm) or

less

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end

of nut goes into taper on wheel.

2.29

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

CAUTION

Front Boots

Rear Boots

WARNING

Tire Pressure

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

Tire Pressure Inspection (Cold)

Front Rear

10 psi (55 kPa) 12 psi (55 kPa)

Drive Shaft Boot Inspection

Inspect the drive shaft boots for damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Refer to Chapter 7 for drive shaft boot replacement.

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with c lean shop towels . Coat the terminals with dielectric grease or petroleum jelly.

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related

accessories contain lead and lead compounds,

and other chemicals known to the State of

California to cause cancer and birth defects or

other reproductive harm.

WASH HANDS AFTER HANDLING.

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from

contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal:

Follow with milk of magnesia, beaten egg, or

Eyes: Flus

Ventilate when charging or using in an enclosed

NOTE: Batteries must be fully charged before use or

tery life will b e re duced by 10 -30% of fu ll

bat potential. Ch arge battery acc ording t o “Charging Procedure” provided in Cha pter 1 0. Do not u se the vehicle’s stator/alternator to charge a new battery.

Drink large quantities of water or milk.

vegetable oil. Call physician immediately.

h with water for 15 minutes and get

prompt medical attention.

Batteries produce explosive gases.

Keep sparks

space. Always shield eyes when

KEEP OUT OF REACH OF CHILDREN.

, flame, cigarettes, etc. away.

working near batteries.

2.30

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MAINTENANCE

CAUTION

Battery Removal

1. Remove the driver’s seat to access the battery.

2. Disconnect the (2) black (neg

3. Disconnect the (2) red (positive) battery cables.

4. Remove the hold-down strap and lift th e battery out the vehicle.

ative) battery cables.

Battery Installation

IMPORTANT: Using a new battery that has not been fully charged can damage the battery and result in a shorter life . It can a lso hinder v ehicle pe rformance. Follow the battery charging procedure in Chapter 10 “Electrical” before installing the battery.

1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with old-down strap.

3. Coat the terminals with dielectric grease or petroleum

elly.

4. Connect and tighten the (2) re

5. Connect a nd tighten the ( 2) black ( negative) cable

ast.

d (positive) cables first.

To reduce the chance of sparks: Whenever

removing the battery, disconnect the black

(negative) cable first. When reinstalling the

battery, install the black (negative) cable last.

rify that cables are properly routed and reinstall the

6. Ve

driver’s seat.

Battery Off Season Storage

Refer to Chap ter 10 “Electrical” for o ff sea son stor age procedures.

2.31

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MAINTENANCE

WARNING

Note for

reassembly

Inspect electrode for wear and buildup

Gap - .0276 - .0315" (0.7 - 0.8 mm)

Spark Plug Gap

Spark Plug Service

1. Remove the dr iver’s sea t a nd d isconnect th e ( -) negative battery cable from the battery.

2. Remove cargo box access panel.

A hot exhaust system and engine can cause

serious burns. Allow engine to cool or wear

protective gloves when removing the spark plugs.

3. Clean top of engine to remove all dirt and debris.

4. Remove the spark plug wire from the engine.

8. Measure gap with a wire gauge. Adjust gap if ecessary by carefully bending the side electrode.

9. If n ecessary, r eplace spa rk p lug with p roper type.

AUTION: Severe engine damage may occur if the

incorrect spark plug is used.

10. Apply Anti-seize compound to the spark plug threads.

11. Install spark plugs and torque to specification.

Recommended Spark Plug:

Champion RG4YCX

Spark Plug Torque:

7 ft. lbs. (10 Nm) Apply Anti-seize

5. Remove spark plug.

6. Inspect electrodes for wear and carbon buildup. Look a sharp outer edge with no rounding or erosion of

for the electrodes.

7. Clean with electrical contact cleaner only.

12. Install spark plug wire into spark plug / engine.

13. Reinstall cargo box access panel.

14. Reinstall the (- ) negative b attery cab le a nd driver’s at.

2.32

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MAINTENANCE

Engine

Ground Cable

Chassis

Ground Terminal

WARNING

Engine To Frame Ground

Inspect ground cable connections. Be sure they are clean and tight.

The engine ground cable runs from the upper starter motor

unting bolt to the chassis ground terminal.

The Chassis ground is located under the drivers seat, near

starter solenoid.

the

STEERING

Steering Inspection

The steering components should be checked periodically for lo ose fa steners, wor n tie ro d e nds, b all jo ints, and damage. Also ch eck to make sure all cotter pins are in place. If cotte r pins are re moved, they mu st not be re– used. Always use new cotter pins.

Replace any wor n or da maged steer ing com ponents.

teering should move freely through the entire range of

S travel without binding. Check routing of all cables, hoses, and wirin g to b e sur e the steer ing mech anism i s n ot restricted or limited.

NOTE: Whenever s teering c omponents are

ed, check front end alignment.

replac

Due to the critical nature of the procedures

outlined in this chapter, Polaris recommends

steering component repair and adjustment be

performed by an authorized Polaris

MSD certified technician.

Use only genuine Polaris replacement parts.

2.33

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Tie Rod

U-Joints

Gearbox

Tie Rod

Check for Loose Wheel or Hub

Steering Wheel Freeplay

Check t he st eering wh eel f or specified freeplay and operation.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8”-1.0” (20-25 mm) of freeplay.

4. If there is exce ssive fr eepla rough, inspect the following components.

• Tie Rod Ends

• Steering Shaft U-Joints

• Steering Gearbox

y or the stee ring feels

Tie Rod End / Wheel Hub Inspection

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• Replace any worn steering components. Steering

ld move freely through entire range of travel

shou without binding.

• Elevate front end of machine so front wheels ar e of

f the ground. Che ck fo r a ny lo oseness in fr ont hub/wheel assemb ly by g rasping the tir e firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

2.34

• If abnormal movement is detected, inspect the hub d whe el assemb ly to deter mine the cau se

an (loose wheel nuts or loose front hub nut).

• Refer to Chap ter 7 “ Final Drive” for fro nt hu b

ser

vice procedures.

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

= In. / mm.

CAUTION

Wheel Toe Alignment Inspection

1. Place ma chine o n a smooth le vel su rface and set steering wh eel in a str aight ah ead position . Secure the steering wheel in this position.

2. Place a chalk mark on the cente approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.

r line of the front tires

Wheel Toe Adjustment

If to e alig nment is inco rrect, mea sure th e dist ance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE: It is impor tant t he h eight of b oth mark s be e

qually positioned to get an accurate measurement.

3. Measure the distance between the marks and record

measurement. Call this measurement “A”.

the

4. Rotate the tires 180 Position chalk marks facing rearward, even with the hub/axle center line.

5. Again measure the distance between the marks and

cord. Call t his m easurement “ B”. Su btract

re measurement “ B” from me asurement “ A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8”, to 1/4”, (.3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement at the rear (B).

(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

° by moving the vehicle forward.

Wheel Toe-Out:

NOTE: Be sure st eering wheel is st raight ahead

ore determining which tie rod needs adjustment.

bef

During tie rod adjustment, it is very important that

the following precautions be taken when

tightening tie rod end jam nuts.

If the rod end is positioned incorrectly it will not

pivot, and may break.

2.35

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

= T

WARNING

Increase

Preload

Decrease

Preload

Cam

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as re

quired to achieve the pr oper toe settin g as

specified in “Wheel Toe Alignment”.

• IMPO

• After alignment is complete, torque jam nuts to

RTANT: When tightening the tie rod end jam

nuts, the rod ends must be held parallel to prevent rod e nd da mage and p remature wear. Dama ge may not be immed iately app arent if done incorrectly.

pecification.

Tie Rod Jam Nut Torque:

12-14 ft. lbs. (16-19 Nm)

SUSPENSION

Spring Preload Adjustment

The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload.

Uneven adjustment may cause poor handling of the

vehicle, which could result in an accident and

serious injury or death. Always adjust both the left

and right spring preloads equally.

Suspension Spring Adjustment

1. Position the vehicle on a lev el su rface and stop the ine.

eng

2. Raise and safely su pport th e fr ont or rear of th e

hicle off the ground to allow the suspension to fully

extend.

NOTE: The tires should not be touching the ground.

3. To adjust the suspension, rotate the

clockwise to incr ease spr ing ten sion or counterclockwise to decrease spring tension.

Shock Spanner Wrench

(PN 2871095)

4. Each notch of the adjustment will add 6% - 8% more

load to the spring over the primary position.

pre

adjustment cam

2.36

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Master Cylinder

Maximum

Minimum

Measure Pad Material

Service Limit:

.040" (1 mm)

Thickness

Measure Brake Disc Thickness

Service Limit:

.170" (4.32 mm)

Front

Disc

Rear

Disc

BRAKE SYSTEM

Brake Fluid Inspection

Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

Brake fluid should be changed every two years. The fluid

uld also be chan ged anytime th e fluid becomes

sho contaminated, the fluid level is below the minimum level, or if th e type and br and of th e flu id in the reservoir is unknown.

The brake fluid master cylinder re through the left front wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK (P).

3. View the brake fluid level in the reservoir. The level uld be between the MAX and MIN level lines.

sho

4. If the fluid level is lower than

brake fluid until it reaches the MAX level line.

servoir can be accessed

the MIN level line, add

Brake Pad / Disc Inspection

1. Check the br ake pa ds for wear, dam age, or looseness.

2. Inspect th e br ake p ad we ar su rface for e xcessive wear.

3. Pads should be changed when the worn to .040” (1 mm).

4. Check surface condition of the brake discs.

friction material is

5. Install th e re servoir ca p and forcefully fo r a fe w se conds a nd ch eck for fluid leakage ar ound the master cylinder fittings an d the brake caliper fittings.

apply the br ake pe dal

5. Measure the th ickness o f the front an d re ar bra ke s.

disc

6. The disc(s) should be replaced if thickness is less than

.170” (4.32 mm).

Brake Hose and Fitting Inspection

Check b rake system hoses and fitting s for cracks, deterioration, ab rasion, an d leaks. Tighten an y loo se fittings and replace any worn or damaged parts.

2.37

9923523 - RANGER RZR 570 Service Manual

MAINTENANCE

Inboard

Pad

Outboard

Pad

Outboard Pad Thickness

New 0.250” (6.35 mm) Limit: 0.190” (4.83 mm)

Inboard Pad Thickness

New 0.300” (7.62 mm) Limit: 0.240” (6.10 mm)

Parking Brake Cable Adjustment (INTL)

When the parking brake is fully engaged and “BRAKE” is displayed on the instrument clu ster, en gine spe ed is limited to 1500 RPM while in gear. If throttle is applied, this limiting fea ture pr events op eration, wh ich pr otects the parking brake pads from excessive wear.

NOTE: Inspect the parking brake cable tension after

he f irst 25 hours of operation and every 100 hours

t of operation af terwards to ens ure prop er cab le tension.

Loss of tension in the p arking brake cable will caus illumination of the parking brake indicator and activation of the limiting feature. If this occurs, inspect an d a djust parking brake cable tension. If performing this service is difficult due to conditions o r location , temporarily disconnect the parking brake switch electrical connector. Reconnect th e co nnector as so on as practicable an d adjust the parking brake cable to proper tension.

1. Pull back on the parking brake lever (located in dash).

2. After 3 t o 4 clic ks “BRAKE ” should display on the nstrument cl uster a nd th e whe els of the vehicle

i should not rotate when turning by hand. After 8 full clicks of lever travel, the vehicle should not roll while parked.

3. If the vehicle moves, adjustment is necessary.

4. Adjust the pa rking brake cable wh ere th e ca ble

ttaches to the caliper mount / shift cable bracket. The

a mount bracket is located on the right-hand side of the transmission.

Parking Brake Pad Inspection (INTL)

Inspect t he p arking br ake ca liper br ake p ad thickness. Replace brake pads if damaged or worn beyond service limit. Replac e caliper ass embly if damage or excessive wear is found. Refer to the following image for brake pad specifications.

Adjustment Procedure: Refer to Chapter 9 “Brakes”

or complete adjustment procedure.

2.38

9923523 - RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

CHAPTER 3

ENGINE / COOLING SYSTEM

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

ENGINE OIL FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

ENGINE SPECIFICATIONS - 1204286 RZR570HO-11 . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES . . . . . . . . 3.8

MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE . . . . . 3.8

CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE . . . . . . 3.9

CYLINDER / OIL FILTER / OIL PUMP / BREATHER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLE

SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER . . . . . . . . . . . . . . . 3.12

PISTON / CRANKSHAFT / BALANCE SHAFT. . . . . . . . .

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM. . . . . . . . . 3.14

COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . .

THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . .

COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

WATER PUMP COVER AND IMPELLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . 3.21

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . .

ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

ENGINE MOUNTING AND TORQUE VALUES . . . . . . . . . . .

ENGINE LUBRICATION SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

SETTING TDC (TOP-DEAD-CENTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

EXHAUST CAMSHAFT DECOMPRESSION MECHANISM . . . . . . . . . . . . . . . . . . . . . 3.41

CAM CHAIN AND GUIDE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . .

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50

PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50

R GEARS / STATOR COVER. 3.11

. . . . . . . . . . . . . . . . . . . . . . . 3.13

. . . . . . . . . . . . . . . . . . . . . . . 3.17

. . . . . . . . . . . . . . . . . . . . . . . . 3.18

. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31

. . . . . . . . . . . . . . . . . . . . 3.35

. . . . . . . . . . . . . . . . . . . . . . . 3.45

3.1

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51

HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52

CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.52

CLEANING THE CYLINDER AFTER HONING . . . . . . . . .

ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53

PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53

PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54

CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57

CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58

VALVE CLEARANCE CHECK / ADJUSTMENT . . . . . . . . . .

INTAKE VALVE LASH - SHIM SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61

EXHAUST VALVE LASH - SHIM SELECTION MA

CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63

CAMSHAFT TIMING - QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66

VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67

TRIX . . . . . . . . . . . . . . . . . . . . . . . . 3.62

ENGINE DISASSEMBLY / INSPECTION - LOWER END. . . . . . . . . . . . . . . . . . . . . . . . 3.68

CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68

FLYWHEEL / STATOR HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68

STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.69

STARTER ONE-WAY CLUTCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.70

FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.71

STATOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.72

STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73

OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73

OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75

CRANKCASE BREATHER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.76

CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.76

BALANCE SHAFT REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.77

CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78

CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78

PTO SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.79

MAG SIDE CRANKCASE BEARING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.80

OIL PICKUP ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.81

OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . . . . . . . . . . . . 3.81

CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.81

ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82

CRANKCASE ASSEMBLY - PTO SIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82

BALANCE SHAFT INSTALLATION / TIMING . . . . . . . . .

FINAL CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.87

. . . . . . . . . . . . . . . . . . . . . . 3.52

. . . . . . . . . . . . . . . . . . . . 3.59

. . . . . . . . . . . . . . . . . . . . . . . 3.84

3.2

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

GENERAL INFORMATION

Special Tools

Tool Description Part Number

Bench Mount Engine Stand Adapter PW-47053

Clutch Center Distance Tool PU-50658

Crankshaft Removal / Installation Tool Kit PU-50784

Cylinder Holding & Camshaft Timing Plate PU-50563

Engine Stand (2” Bore) PU-50624

Engine Stand Adapter (Mounts To The Engine) PU-50824

Engine Stand Sleeve Adapter (Use With 2” Bore Stand) PU-50625

Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand) PW-47054

Flywheel Puller PA-49316

Oil Filter Wrench PU-50105

Oil Pressure Gauge PV-43531

Oil Pressure Gauge Adapter PU-50569

Stator Cover Removal Handles PA-49317

Valve Spring Compressor PV-1253 or PV-4019 (Quick Release)

Valve Spring Compressor Adapter PV-43513-A

Water Pump Mechanical / Oil Seal

SPX Corporation - 1-800-328-6657 http://polaris.spx.com/.

Installation Kit PU-50689

Engine Lubrication Specifications

Oil Capacity Approx. 2 Quarts (1.9 L)

Oil Filter Wrench PU-50105 or 2.5” (64 mm)

Oil Type

Oil Pressure

Minimum Spec

(using Polaris PS-4 Plus

at operating temperature)

ification

Polaris PS-4 Plus

Synthetic En

10 PSI @ 1200 RPM

40 PSI @ 7000 RPM

gine Oil

(Minimum)

3.3

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

PV-43531

PU-50569

Image for Reference Only

= T

Oil Pressure Test

1. Attach the Oil Pr essure Gauge Adapter (PU-50569)

to the Oil Pressure Gauge (PV-43531).

Oil Capacity Approx. 2 Quarts (1.9 L)

Oil Filter Wrench PU-50105 or 2.5” (64 mm)

Oil Pressure Gauge Adapter: PU-50569

Oil Pressure Gauge: PV-43531

2. Remove the seats and engine service panel.

3. Clean the area around the main oil gallery plug (A),

cated on the oil filter adapter housing.

4. Remove the plu g ( A) and in sert the oil pressure

dapter.

Oil Type

Oil Pressure

mum Specification

Mini

(using Polaris PS-4 Plus

at operating temperature)

6. Upon assembly, torque the crankcase gallery plug to pecification.

Oil Gallery Plug:

11 ft. lbs. (15 Nm)

Polaris PS-4 Plus

Synthe

10 PSI @ 1200 RPM

40 PSI @ 7000 RPM

tic Engine Oil

imum)

(Min

imum)

(Min

5. Start engine an d a llow it to r each op erating perature, monitoring gauge indication.

tem

NOTE: Test results ar e bas ed on the us e of the

commended engine oil (Pola ris PS- 4 Plus) at

re operating temperature, and may vary considerably if any ot her oil is used or if engine is not up to temperature.

3.4

9923523 - 2012 RANGER RZR 570 Service Manual

Engine Oil Flow Chart

ENGINE / COOLING SYSTEM

3.5

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

ENGINE SERVICE SPECIFICATIONS

Engine Specifications - 1204286 RZR570HO-11

CAMSHAFT / CYLINDER HEAD / CYLINDER (IN. / MM)

Cam Lobe Height - Intake 1.5704" ± 0.0038" (39.89 ± 0.097 mm)

Cam Lobe Height - Exhaust 1.5405" ± 0.0038" (39.13 ± 0.097 mm)

Camshaft Journal O.D. - All (Standard) 0.9029" - 0.9037 " (22.933 - 22.954 mm)

Camshaft Journal O.D. - All (Service Limit) 0.9025" (22.923 mm)

Camshaft

Cylinder Head

Valve Seat

Valve Guide Valve Guide Inner Diameter 0.2165" - 0.2171" (5.500 - 5.515 mm)

Valve

Valve Spring

Cylinder

Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)

Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)

Camshaft Oil Clearance (Standard) 0.0018" - 0.0034" (0.046 - 0.088 mm)

Camshaft Oil Clearance (Service Limit) 0.0047" (0.121 mm)

Camshaft End Play (Standard) 0.0069" - 0.0128" (0.175 - 0.325 mm)

Camshaft End Play (Service Limit) 0.0157" (0.4 mm)

Cylinder Head - Surface Warp Limit 0.0024" (0.060 mm)

Cylinder Head - Standard Height 4.745" ± 0.0020" (120.53 ± 0.05 mm)

Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)

Valve Seat - Contacting Width - Intake (Service

Lim

Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)

Valve Seat - Contacting Width - Exhaust (Service

Lim

Valve Seat Angles 30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°

Valve Lash (Cold) - Intake 0.005" - 0.007" (0.125 - 0.175 mm)

Valve Lash (Cold) - Exhaust 0.00

Valve Stem Diameter - Intake 0

Valve Stem Diameter - Exhaust 0.2147" - 0.2153" (5.455 - 5.470 mm)

Valve Stem Oil Clearance - Intake 0.0003" - 0.0015" (0.010 - 0.040 mm)

Valve Stem Oil Clearance - Exhaust 0.0011" - 0.0023" (0.030 - 0.060 mm)

Valve Stem Overall Length - Intake 3.7704" (95.77 mm)

Valve Stem Overall Length - Exhaust 3.7964" (96.43 mm)

Valve Spring Free Length (Standard) 1.7263" (43.85 mm)

Valve Spring Free Length (Service Limit) 1.683" (42.75 mm)

Cylinder - Surface Warp Limit (mating with cylinder head)

Cylinder Bore - Standard 3.8976" ± 0.0003" (99.0 mm ± 0.008 mm)

Cylinder Out of Round Limit 0.001" (0.025 mm)

Cylinder Taper Limit 0.001" (0.025 mm)

Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm)

0.0551" (1.4 mm)

0.0748" (1.9 mm)

- 0.010" (0.152 - 0.254 mm)

.2155" - 0.2161" (5.475 - 5.490 mm)

0.00098" (0.025 mm)

3.6

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT (IN. / MM)

Piston - Standard O.D. - Measured 90 degrees to

in, 0.47 in. (12 mm) up from piston skirt. See text.

Piston

Piston Pin

Piston Ring

Connecting

Rod

Crankshaft

Balance Shaft Bearing Journal O.D. (Standard) 1.1798” - 1.1802" (29.969 - 29.979 mm)

Piston Pin Bore I.D. (Standard) 0.8662” - 0.8665” (22.004 - 22.010 mm)

Piston Pin Bore I.D. (Service Limit) 0.8677" (22.042 mm)

Piston Pin O.D. (Standard) 0.8659" - 0.8661" (21.995 - 22.000 mm)

Piston Pin O.D. (Service Limit) 0.8651" (21.975 mm)

Top Ring (Standard) 0.0059" - 0.0122" (0.15 - 0.31 mm)

Top Ring (Service Limit) 0.0137" (0.35 mm)

Installed

Ring to

oove

Clearance

Connecting Rod Small End I.D. (Standard) 0.8665" - 0.8670" (22.010 - 22.023 mm)

Connecting Rod Small End I.D. (Service Limit) 0.8682" (22.053 mm)

Connecting Rod Big End I.D. See Service Procedure Listed In This Chapter

Main Journal O.D. (Service Limit) 1.6137" (40.990 mm)

Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter

Second Ring (Standard) 0.00

Second Ring (Service Limit) 0.0220" (0.56 mm)

Oil Control Rails (Standard) 0.0098" - 0.0401" (0.25 - 1.02 mm)

Oil Control Rails (Service Limit) 0.0480" (1.22 mm)

Top Ring (Standard) 0.0011" - 0.0037" (0.030 - 0.095 mm)

Top Ring (Service Limit) 0.0042" (0.108 mm)

Second Ring (Standard) 0.0007" - 0.0029" (0.020 - 0.076 mm)

Second Ring (Service Limit) 0.0035" (0.089 mm)

3.8957” - 3.8968” (98.953 - 98.980 mm)

94" - 0.0196" (0.24 - 0.50 mm)

3.7

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES

Main Engine Components - Torque Specification and Sequence

3.8

9923523 - 2012 RANGER RZR 570 Service Manual

Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve

Replace Bolts if

Loosened or Removed

ENGINE / COOLING SYSTEM

3.9

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

Replace Bolts if

Loosened or Removed

Apply Loctite® 272™

Cylinder / Oil Filter / Oil Pump / Breather

3.10

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

Replace Bolts if

Loosened or Removed

Apply Loctite® 272™

Loosened or Removed

Replace Gasket if

Loosened or Removed

Replace Nut if

Loosened or Removed

Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

3.11

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

Apply Anti-seize

Replace Bolts if

Loosened or Removed

Spark Plugs / Starter / Throttle Body / Valve Cover

3.12

9923523 - 2012 RANGER RZR 570 Service Manual

Piston / Crankshaft / Balance Shaft

ENGINE / COOLING SYSTEM

3.13

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

Water Pump

Upper Engine Hose

Lower Engine

Hose

Bypass Hose

Radiator

Recovery

Bottle

Upper Radiator

Hose

Pressure Cap

Filler Neck

Hoses

Cooling Fan

ENGINE COOLING SYSTEM

Cooling System Exploded View and Coolant Flow Diagram

3.14

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

WARNING

Test H ere

Cooling System Specifications

Condition Coolant Temperature °F (°C)

Room Temperature 68° F (20° C)

Thermostat Open 180° F (82° C)

Fan Off 192° F (89° C)

Fan On 198° F (92° C)

Thermostat Full Open Lif

Engine Temperature

rheat Indicator

Ove

Engine Protection Ignition Misfire

Engine Protection

down

Shut

Item Specification

Cooling System Capacity 4.25 qts. (4 l)

203° F (95° C)

233° F (112° C)

236° F (113° C)

257° F (125° C)

Cooling System Pressure Test

1. Remove the hood from the front cab.

Never remove pressure cap when engine is

warm or hot. The cooling system is under

pressure and serious burns may result.

Allow the engine to cool before servicing.

2. Remove pressure cap and pr system using a commercially available pressure tester.

essure test the cooling

Pressure Cap Relief 13 PSI

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

Recommended Coolant

Use only high quality antif re distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.

CAUTION: Using to a buildup of deposits which may restrict coolant flow and reduce he at dissip ation, r esulting in p ossible engine damage. Pola ris Pre mium 60 /40 An tifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

tap water in the cooling system will lead

eze/coolant m ixed with

3. The system must maintain 10 psi for five minutes or

onger. If pressure loss is evident within five minutes,

l check the filler neck, radiator, hoses, clamps and water pump weep hole for leakage.

3.15

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

CAUTION

Flush radiator fins

in this direction

Pressure Cap Test

1. Remove th e ho od fro m th e fro nt cab (see “WARNING” under “Cooling System Pressure Test”).

2. Remove pressure cap (A) and test using a pressure

tester (commercially available).

cap

3. The pressure cap r elief pressure is 13 psi. Re place cap

if it does not meet this specification.

Radiator

1. Check ra diator (A) air passages for r estrictions or damage.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions wit pressure water.

h compressed air or low

Washing the vehicle with a high-pressure

washer could damage the radiator fins and

impair the radiators effectiveness. Use of a high-

pressure washer is not recommended.

3.16

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

WARNING

Drain Here

Recovery

Engine

T-Fitting

Radiator

Fan Motor Asm.

Screws

Grommets

Inserts

Hose

Outlet Hose

Engine

Inlet Hose

Coolant Drain / Radiator Removal

Coolant Drain

1. Remove the hood from the front cab.

Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool.

2. Slowly remove the pressure cap to relieve any cooling tem pressure.

sys

3. Place a suitab le drain p an underneath the r adiator

g on the front right-hand side of the vehicle.

fittin

4. Drain the coolant from the radiator by removing the

wer coo lant hose from the r adiator as sho wn.

lo Properly dispose of the coolant.

Radiator Removal

1. Remove the front bumper (see Chapter 5).

2. Remove the upper engine outlet hose and recovery ose from the top of the radiator.

3. Remove the (2) upper radiator retaining bolts and the

4) bolts retaining the lo wer radiator mount bracket.

( Remove the bracket from the frame.

4. Disconnect th e fa n mo tor an d re move the radiator

m the vehicle. Take care not to damage the cooling

fro fins.

5. Allow coolant to completely drain.

6. Place a s uitable drain p an u nderneath th e lower ngine hose on the right-hand rear side of the vehicle.

5. Reverse procedure for installation.

7. Remove the hose and completely drain the engine.

3.17

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

WARNING

= T

WARNING

CAUTION

MAX Line

Thermostat Replacement

1. Remove the hood from the front cab.

The cooling system is under pressure and

serious burns may result.

Allow the engine to cool before servicing.

2. Remove the pr essure cap pressure (see “Pressure Cap Test”).

3. Drain coolant to a level below the thermostat housing.

4. Remove the cargo box access panel.

5. Remove the spark plug wire from the engine.

6. Remove th e (2 ) bo lts (X) retai ning the th ermostat cover.

to reliev e any sys tem

Cooling System Bleeding Procedure

Always wear safety glasses and proper shop

clothing when performing the procedures in this

manual. Failing to do so may lead to possible

injury or death.

Use caution when performing these procedures.

Coolant may be hot and may cause

severe injury or burns.

NOTE: If the coolant level is LOW in the radiator, or if the re are leaks in th e system, the coolant system will not draw coolant from the reservoir tank.

NOTE: It may be necessary to safely raise the front

the vehicle 1 2” ( 30 c m) to blee d the c ooling

of system.

7. Lift the co ver from th e en gine a nd r emove the

rmostat.

the

8. Reverse th is p rocedure for in stallation. Re place

rmostat seal if wor n or da maged. T orque

the thermostat cover bolts to specification.

Thermostat Cover Bolts:

7.5 ft. lbs. (10 Nm)

9. Be sure to properly fill and bleed cool outlined in this chapter.

ing system as

1. Allow engine and cooling system to completely cool.

Be sure the engine has cooled and no pressure is built up in the cooling system before removing

the pressure cap. The coolant may be hot and

could cause severe injury or burns.

2. Remove the hood.

3. Remove the recovery to the MAX line.

bottle cap (A) and fill the bottle

3.18

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

= T

4. Remove the pressure cap (B) and add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.

5. Remove the cargo box access to th e coola nt bleed screw that is on top of the thermostat housing.

6. Open the bleed screw (C) to allow any trapped air to

cape.

7. Fill the radiator until a steady stream of coolant begins to drain out of the bleed screw (C).

cover to gain access

13. Tighten the b leed scr ew to coolant and properly install the pressure cap.

Coolant Bleed Screw:

6 ft. lbs. (8 Nm)

14. Fill the recovery bottle to the MAX line.

15. Reinstall the hood.

16. Reinstall cargo box access cover.

sp ecification, to p off

8. Tighten the b leed scr ew to sp ecification, to p o ff lant and properly install the pressure cap.

coo

Coolant Bleed Screw:

6 ft. lbs. (8 Nm)

9. Start the en gine and allow it to idle until the coolant

fan has cycled.

10. Allow engine and cooling sys

down (see CAUTION).

11. Remove the pressure cap. Add the necessary amount

olaris Premium Antifree ze to the radiator filler

of P neck.

12. Open th e ble ed scre w to allo w any tr apped air to

scape. Close the bleed screw once a steady stream

e of coolant begins to drain out.

tem to completely cool

3.19

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

CAUTION

= T

Finger Tighten

(Reverse Threads)

9 ft. lbs.

(12 Nm)

9 ft. lbs.

(12 Nm)

WATER PUMP SERVICE

Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)

NOTE: The wate r pu mp cov er, ga sket and impe ller can be serviced with the stator cover installed on the engine.

1. Allow engine and cooling system to completely cool.

Be sure the engine has cooled and no pressure is built up in the cooling system before removing

the pressure cap. The coolant may be hot and

could cause severe injury or burns.

2. Remove both seats and the engine service panel.

3. Disconnect the (-) negative battery cable.

4. Remove all debris and thoroughly clean water pump rea and right-hand side of engine block.

5. Remove the hood.

11. Using an 8 mm socket, r emove th e water pum p peller (D).

NOTE: The wa ter pump impe ller (D) use s rev erse

threads.

(LH)

12. Inspect the water pum p co ver an d impe ller for

amage. Replace as necessary.

13. Follow this pro cedure in reverse to asse mble th e

ter pump impeller and cover. Always use a new

wa water p ump co ver g asket. To rque a ll fa steners in sequence to specification.

6. Remove the pressure c

7. Completely dr ain co oling syste m and engine as outlined in this

8. Raise a nd safely support the vehicle. Rem ove the

ight-hand rear wheel.

9. Remove th e (8 ) bolts (A) a ttaching the water pump

to the stator cover.

cover

10. Remove the water pump cover (B) and water pump

ver gasket (C). Discard the water pump gasket (C).

chapter.

ap from the filler neck.

Water Pump Cover Fastener Torque:

9 ft. lbs. (12 Nm)

14. Fill and bleed cooling s ystem as outlined in this apter.

3.20

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

CAUTION

Water Pump Mechanical Seal / Oil Seal Replacement

NOTE: The s tator cov er must be re moved from the engine t o s ervice the wa ter pump drive sh aft, oil seal, mechanical seal and bearing.

1. Allow engine and cooling sys

Be sure the engine has cooled and no pressure is built up in the cooling system before removing

the pressure cap. The coolant may be hot and

could cause severe injury or burns.

2. Remove both seats and the engine service panel.

3. Disconnect the (-) negative battery cable.

4. Remove all debris and thoroughly clean water pump rea and right-hand side of engine block.

5. Remove the hood.

6. Remove the pressure cap from the

tem to completely cool.

filler neck.

10. Remove the CPS sensor from the stator cover on the ight-hand side of the engine. Inspect CPS O-ring and

r replace if needed.

11. Remove the oil dipstick.

12. Remove the ( 8) bolts (A) r etaining the water pump

er to the stator cover.

cov

13. Remove the water pump cover (B) and water pump

er gasket (C). Discard the water pump gasket (C).

cov

7. Completely drain c ooling syst outlined in this chapter.

8. Raise an d s afely support the right-hand rear wheel.

9. Disconnect the stator wire connector and cut the tie

ap s ecuring th e w iring t o t he fr ont engine mount

str bracket.

em and engine as

ve hicle. Rem ove the

14. Remove the water pump impeller (D).

NOTE: The water pump impeller (D) uses reverse

H) threads.

3.21

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

CAUTION

PA-49317

15. Remove the (13) bolts securing the stator cover to the engine.

16. If needed, install the stator cover removal handle tool

PA-49317) to the water pump cover bolt holes to aid

( in stator cover removal.

The flywheel contains powerful magnets. Use

caution when removing the stator cover.

DO NOT place fingers between cover and

crankcase at any time during the removal

process or injury could result.

18. Bring the sta tor cover assemb ly to a clea n work ch.

ben

19. Using a b rass dr ift, re move th e water pum p dr ive

aft. Be sur e not to da mage the thr eads. Inspe ct

sh shaft for wear or damage, replace if necessary.

20. Extract the mechanical seal (E) and the oil seal (F)

om the stator cover.

17. Remove and discard the stator cover gasket.

Be sure engine coolant does not contaminate the

engine oil during stator cover service.

21. Press out the water pump drive shaft bearing (G) from

e sta tor cover. Disca rd bea ring an d replace with

th new.

3.22

9923523 - 2012 RANGER RZR 570 Service Manual

Water Pump Assembly

CAUTION

PU-50869

Item #1 Item #2

Item #3

PU-50869

Item #1

PU-50869

Item #1

1. Thoroughly clean the stator cover.

ENGINE / COOLING SYSTEM

2. Press in a ne

until it is fully seated in the cover.

Be sure bearing is fully seated in cover or severe

3. Clean and de-grease the water pump drive shaft (H).

w water pump drive shaft bearing (G)

engine damage may result.

5. Install the water pump drive shaft ho lding tool ( Item #1) in kit PU-50869. the as sembly u p-side-down so the spe cial tool PU50869 is supporting the assembly.

Hold the tool in position and flip

4. Press in th e wa ter pu mp dr ive shaft (H) into the earing using PU-50869 Item #1.

3.23

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

CAUTION

PU-50869

Item #2

PU-50869

Item #3

Water Pump Alignment Detail View

Crankshaft

Oil Seal

Mechanical

Impeller

Seal

Drive Shaft

6. Lubricate the new wa ter p ump oil se al w ith c lean

engine oil.

7. Use the water pump oil seal installation

PU-50869 to fully install the new

tool in kit

water pump oil seal

(I).

Be sure the oil seal is fully seated in cover or

severe engine damage may result

10. Align the water pump drive slot as shown below.

11. Align th e water p ump dr ive sh aft b lade as sh own w.

belo

12. Apply a small amount of crankcase sealant to the area

indicate

d below (A).

8. Use the water pump mechanical seal installation tool in kit PU-50869

to fully install the new water pump

mechanical seal (J) until it is fully seated in the cover.

9. Install a new stator

cover gasket onto the engine.

13. If needed, install the stator cover removal handles tool PA-

49317 to the water cover bolt holes to aid in stator

cover installation.

3.24

9923523 - 2012 RANGER RZR 570 Service Manual

14. While installing the stator cover to the engine, slightly

CAUTION

PA-49317

9 ft. lbs. (12 Nm)

= T

= In. / mm.

Water Pump Drive Shaft

Mechanical Seal

Stator Cover

Finger Tighten

(Reverse Threads)

rotate the water pump impeller to verify the crankshaft slot and the water pump drive shaft blade are properly engaged. Verify the stator cover is laying flat on the engine case.

ENGINE / COOLING SYSTEM

Stator Cover and Water Pump Cover

9 ft. lbs. (12 Nm)

The flywheel contains powerful magnets. Use

caution when installing the stator cover.

DO NOT place fingers between cover and

crankcase at any time during the removal and

installation process or injury could result.

If the water pump drive shaft blade and slot in the

crank shaft are not in alignment during the

installation process, severe engine damage may

result.

15. Install and to rque the stator cover fa steners in sequenc

e to specification.

16. Measure the installed height of the new m

seal a s sh own b elow. If not within sp ecification, remove and discard the mechanical seal and properly install new mechanical s eal as outlined in this chapter.

Mechanical Water Pump Seal Installed Height:

0.280” - 0.287” (7.2 +/- 0.1 mm)

17. Install the water pu mp imp

only.

NOTE: The water pump impeller (K) uses reverse

H) threads.

eller (K). Finger tighten

echanical

18. Install a ne

9923523 - 2012 RANGER RZR 570 Service Manual

w water pump cover gasket.

3.25

ENGINE / COOLING SYSTEM

= T

9 ft. lbs.

(12 Nm)

19. Install th e water pu mp co ver to the stator cover. Torque all fasteners in sequence to specification.

20. Install the oil dipstick.

21. Install the coolant hose to the water pump cover and

ten hose clamp.

tigh

22. Connect the stator wire connector and install a new

p securing the wiring to the front engine mount

tie stra bracket.

23. Install the CPS sen sor into the stator cover. Inspect

O-ring and replace if needed.

CPS

24. Install the right-hand rear wheel and torque the wheel

uts to specification. Safely lower vehicle.

ENGINE SERVICE

Accessible Engine Components

The followin g com ponents can b e serviced or re moved with the engine installed:

• Camshaft

• Camshaft Sprockets

• Cylinder Head and Gaskets

• Cylinder and Gaskets

• Piston and Rings

• Flywheel

• Starter Motor / Idler Gear Asm

• Stator (Alternator)

• Thermostat

• Valve Cover

•Water Pump

• Camshaft Timing Chain and Guides

• Crankshaft Seal (PTO)

• Oil Pump / Oil Pump Sprocket or Chain

The following c omponents require e ngine re moval for se

rvice:

• Counterbalance Shaft and Bearings

Wheel Nuts:

Steel Wheels: 27 ft. lbs. (37 Nm)

Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

25. Install both seats and the engine service panel.

26. Connect the (-) negative battery cable.

27. If the engine oil was contaminated during this service

rocedure, perform an engine oil change as outlined

p in Chapter 2. DO NOT run the engine until coolant has been added to the cooling system.

28. Fill cooling system with rec the system of air as outlined in this chapter.

29. Check for leaks.

ommend coolant and bleed

• Crankshaft and Bearings

• Crankcase

• Oil Pressure Regulator

• Oil Pump Pickup Assembly

Top-End Service (Engine in Chassis)

ALL of the top-end engine components can be serviced while the engine is mounted in the chassis.

3.26

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ENGINE / COOLING SYSTEM

CAUTION

WARNING

Spring Style

Clamp

Engine Removal

IMPORTANT: Some engine repair procedures can be performed with out removing the engine as sembly from th e ve hicle. Re fer to “Acc essible Engine Components” for further information.

NOTE: The use of an overhead or port able engine

ist is the only recommended method for removing

ho and installing the engine.

NOTE: Have an a ssistant help gu ide the eng ine in

nd out of the vehicle while using an engine hoist to

a prevent pe rsonal injur y or dama ge to vehicle components.

Correct Drive Clutch Puller P/N PA-48595

3. Drain the engine oil and engine coolant prior to engine emoval (see Chapter 2).

4. Remove the sea ts an d en gine service pan el (see

apter 5).

5. Disconnect th e ( -) neg ative ba

battery.

6. Remove th e r ear bu mper and cargo b ox as a n

embly (see Chapter 5).

ass

ttery ca ble fr om the

Always wear safety glasses and proper shop

clothing when performing the procedures in

this Service Manual.

Failing to do so may lead to possible injury.

1. If vehicle was recently operated, allow it to cool down before

2. Thoroughly clean the engine and chassis.

attempting to perform any work.

7. Loosen the (3) clam ps se curing th e int ake ba ffle ssembly to the air box lid, inn er clutch cover and

a engine crankcase vent. Remove the air intake baffle / intake ho ses / engine cran kcase vent tube an assembly as shown below.

8. Elevate the rear of the vehicle off the ground using a

suitable lift

and remove the left rear wheel.

3.27

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ENGINE / COOLING SYSTEM

9. Remove the outer clutch cover, drive belt, drive clutch, driven clutch and inner clutch cover (see Chapter 6). Make note of hose and wire routings for reassembly.

IMPORTANT: Be sure to use the correct Drive Clutch Puller

10. Disconnect the stator wire connector and cut the tie

11. Remove the CPS sensor from the stator cover on the

(PA-48595) to prevent damage to crankshaft.

p secur ing the wir ing to the fro nt eng ine mou nt

stra bracket. Replace tie strap for engine installation.

ight-hand sid e of the en gine. Plug CPS h ole with

r clean shop towel. Inspect CPS O-ring and replace if needed.

12. Disconnect the IAC valve (A), TPS (B), T-MAP sensor (C), har

13. Disconnect the fuel injector harness lead (D) from the fuel injec

14. Properly relieve fuel pressure from the fuel rail.

15. Place a shop to beneath the fuel line quick connector to from the fuel rail by pressing in on the quick connector tabs.

16. Move fue l line to th e left-h and sid e of th e en gine co installation.

ness leads from the throttle body.

tor.

catch any excess fuel. Disconnect the fuel line (E)

mpartment. Make note of line routing for

3.28

17. Disconnect the ignition coil har ness co nnector an d

ove the spark plug wire from the engine.

rem

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

18. Remove t he ( 8) fa steners securing t he ( 2) b olt in braces to the veh icle main fra me. Ma neuver the braces for engine removal clearance. Note the routing of the transmission breather hose and wire harness.

19. Remove (+) positive cable from the starter motor.

20. If desired, remov e the re maining s and remove the starter motor from the engine.

21. Remove (-) negative cable from the starter mounting

lt.

tarter motor bolt

22. Loosen the hose clamp (F) securing the throttle body the air box. L ift air box up and rea rward a s an

to assembly to disengage it from the throttle body.

23. Loosen the hose clamp (G) securing the throttle body the engine intake boot. Remove throttle body from

to the engine and wrap it with a clean shop towel. Place throttle body on the left-hand side frame rail area.

IMPORTANT: Be sure dirt and debris do not enter the

ngine, a ir box or t hrottle bod y. Use clean sho p

e towels to plug engine and air box intake holes.

24. Disconnect the upper en gine coo lant h ose ( H),

ass hose (I) and ECT (J) harness connector.

byp

3.29

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ENGINE / COOLING SYSTEM

Discard

PU- 50824

Bolts From The Center Outward

25. Remove the (3 ) he x bolts (K) securing the exhaust head pipe to the eng ine. Remo ve th e (3 ) r ubber exhaust hangers (L) securing the exhaust system to the main frame. Discard the exhaust seal and replace with new for reassembly.

26. Maneuver the exhaust system towards the right-hand

of the vehicle to gain engine removal clearance.

side Removal of the exhaust system from the chassis is not needed.

27. Place a s upport in -between th e main fra me and

nsmission case. Do not pinch brake line.

tra

30. Remove the ( 8) b olts (N) securing th e cou pler ckets to the engine and transmission.

bra

31. Loosen the (2) bolts and nuts (O) so the engine mount cket can be slightly tilted away from engine.

bra

32. With the h elp of an assista nt an d the en gine ho ist,

the engine vertically out of the vehicle frame.

raise

NOTE: Have a n ass istant help guide t he e ngine in and out prevent per sonal injury or dama ge t o th e ve hicle components.

of the vehicle while using an engine hoist to

28. Use an overhead or portable engine hoist and suitable gine s traps t o s ecure the engine in its cu rrent

en position.

29. Remove the (4) bolts and nuts (M) securing the engine

to the front

motor mount bracket.

33. Install the engine stand adapter (PU-50824) onto the ine PTO side mounting ears as shown below.

eng

34. Select th e pr oper eng ine stand slee ve adapter an d

ll it onto the engine stand adapter.

insta

• Sleeve adapter for a 2” bore engine stand:  (PU-50625)

• Sleeve adapter for a 2.375” bore engine stand:  (PW-47054)

35. Place engine onto the engine stand (PU- 50624) for rvice.

3.30

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ENGINE / COOLING SYSTEM

Drive Clutch Bolt Installed

PU-50658

Tool Fully Seated Inward

Engine Installation

Use the following pr ocedure to re install th e eng ine assembly.

1. Attach en gine with suit a overhead or portable engine hoist.

2. Remove the engine stand adapter plate.

3. Use the ove rhead or p ortable engine ho ist a nd

le e ngine straps to lower the en gine in to the

suitab vehicle frame.

NOTE: Have an a ssistant help gu ide the eng ine in

nd out of the vehicle while using an engine hoist to

a prevent pe rsonal injur y or dama ge to vehicle components.

4. By hand, install the (4) front engine mount bolts and

(A). Do not tighten at this time.

nuts

5. Instal the (4) engine to tran and instal the ( 8) bo lts and washe rs ( C). Do no t tighten fasteners at this time.

ble lift ing str aps t o a n

smission coupler plates (B)

6. Install the Clutch Ce nter Distance To onto th e cr ankshaft and tr ansmission in put shaft t o properly position the clutch center distance. 



The pictures below show the to installed.

ol (PU-50658) properly

ol (PU-5 0658)

IMPORTANT: DO NOT torque f

asteners at this time.

3.31

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ENGINE / COOLING SYSTEM

= T

55 ft. lbs

(74.5 Nm)

40 ft. lbs.

(54 Nm)

40 ft. lbs.

(54 Nm)

= T

New

18 ft. lbs.

(24.5 Nm)

7. In seq uence, torque the (8) engine coupler br acket fasteners to specification.

Rear Engine Coupler Fastener (In Sequence):

55 ft. lbs. (74.5 Nm)

8. In a criss-cross pattern, to mount fasteners to specification.

rque the (4 ) fro nt eng ine

10. Remove the lifting str aps and over head or po rtable eng

ine hoist an d r emove th e sup port pr eviously installed under the tra nsmission case du ring th e engine removal process.

11. Reposition th e e xhaust system a nd insta ll the (3) ber exhaust hangers, new exhaust seal and the (3)

rub head p ipe bo lts. To rque he ad pipe b olts to specification.

Front Engine Mount Fasteners:

40 ft. lbs. (54 Nm)

9. Torque th e (2) front center iso lator bolts to ification.

spec

Isolator Center Bolt:

40 ft. lbs. (54 Nm)

Exhaust Head Pipe Bolts:

18 ft. lbs. (24.5 Nm)

12. Install the (3) coolant hoses onto the engine.

13. Install the throttle body and air box. Tighten the hose mps that secure the throttle body to the intake boot

cla and air box.

14. Install the lower stater motor

starter motor mounting boss.

15. Instal the starter motor onto the engine.

16. Install the starter motor and ba

in Chapter 10.

Starter Motor Fastener:

7 ft. lbs. (10 Nm)

b olt through the lower

ttery cables as outlined

3.32

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ENGINE / COOLING SYSTEM

= T

17 ft. lbs.

(23 Nm)

40 ft. lbs.

(54 Nm)

17. Connect the harness leads to the IAC valve (D), TPS (E), T-MAP sensor (F). Verify routing is correct.

18. Connect the fuel injector harne injector.

19. Connect the fuel line (H) to the fuel rail.

ss lead (G) to the fuel

20. Install the (8) fasteners securing the (2) bolt in braces e ve hicle m ain frame. Torque fas teners to

to th specification. Be sure the routing of the transmission breather hose and wire harness is correct.

Rear Bolt in Brace Fastener Torque:

17 ft. lbs. (23 Nm)

Front Bolt in Brace Fastener Torque:

40 ft. lbs. (54 Nm)

21. Connect the ignition coil harness connector and install

e spark plug wire.

22. Install the CPS and mounting bolt into the stator cover

d torque to specification.

CPS Fastener Torque:

9 ft. lbs. (12 Nm)

23. Connect the stator wire connector and install a new

strap to secure the wiring to the front engine mount

tie bracket.

24. Install the inner clutch cover as outlined in chapter 6.

25. Install the dr ive clutch, driven clutch, belt and outer

ch cover as outlined in Chapter 6. Be sure all hose

clut and wire routings are correct. Torque all fasteners to specification as outlined in Chapter 6.

26. Install the in take ba ffle as sembly. Se cure the 3

mps that attach the a ssembly to the crankc ase

cla vent, air box lid and inner clutch cover.

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3.33

ENGINE / COOLING SYSTEM

= T

CAUTION

27. Install the rear bumper and cargo box assembly as outlined in Chapter 5.

28. Install the left-hand rear wheel and torque wheel nuts to specification.

Wheel Nuts:

Steel Wheels: 27 ft. lbs. (37 Nm)

Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

29. Remove the pressure cap and fill the through the filler neck with properly mixed anti-freeze / coolant.

30. If the e ngine o il wa s com pletely d rained, a dd

roximately 2 quarts (1.9 L) of Polaris PS-4 Plus

app Synthetic Engine Oil into the crankcase.

31. Install a new oil filter. Lubricate the seal with engine

rior to installation (see Chapter 2 “Maintenance”).

oil p

32. Connect the (-) negative batter

33. Install the engine service panel and seats.

34. Follow the “Cooling System Bleeding Procedure” as

ed in this chapter.

outlin

35. Start engine and check for any oil or coolant leaks.

36. Check the engine oil level (see Chapter 2).

37. Refer customer to “En gine Bre ak-In Peri od” up on

urning vehicle to customer.

ret

cooling system

y cable to the battery.

Engine Break-In Period

The break-in period con sists o f the first 25 h ours o f operation, or the time it takes to use 15 gallons (57 liters) of fuel. Careful treatment of a ne w e ngine a nd d rive components will result in more efficient performance and longer life for these components.

Use only Polaris PS-4 PLUS

Synthetic Engine Oil.

Never substitute or mix oil brands.

Serious engine damage and voiding of

w a r r a n t y c a n r e s u l t .

Do not operate at full throttle or high speeds for

extended periods during the first three hours of

use. Excessive heat can build up and cause

damage to close fitted engine parts.

1. Fill fuel tank with unleaded fuel which has a minimum ump octane number of 87 = (R+ M)/2.

2. Refer to Chapter 2, “Engine Oil

indicated on oil tank dipstick. Add oil if necessary.

3. Drive slo wly at first to g radually b ring engine up to

erating temperature.

4. Vary throttle positions. Do not operate at sustained

le or sustained high speed.

5. Perform regular checks on fluid le vels, controls and ll important bolt torques.

6. Change oil an d oil filter a fter br eak-in pe riod at 25

urs.

Level”. Check oil level

3.34

9923523 - 2012 RANGER RZR 570 Service Manual

Engine Mounting and Torque Values

Front Engine Mount

Isolator Mount

Exhaust System

25 ft. lbs.

(34 Nm)

18 ft. lbs.

(24.5 Nm)

40 ft. lbs. (54 Nm)

25 ft. lbs.

(34 Nm)

40 ft. lbs. (54 Nm)

55 ft. lbs. (74.5 Nm)

Coupler Brackets

40 in. lbs.

(4.5 Nm)

Gasket

Seal

See Torque Sequence

See Engine Installation For

Critical Torque Procedure

40 ft. lbs. (54 Nm)

ENGINE / COOLING SYSTEM

Engine Lubrication S

Oil Capacity Approx. 2 Quarts (1.9 L)

Oil Filter Wrench PU-50105 or 2.5” (64 mm)

Oil Pressure

Minimum Specification

(using Polaris

operating temperature)

Oil Type

PS-4 Plus at

pecifications

Synthetic Engine Oil

10 PSI @ 1200 RPM

40 PSI @ 7000 RPM

Polaris PS-4 Plus

(Minimum)

9923523 - 2012 RANGER RZR 570 Service Manual

3.35

ENGINE / COOLING SYSTEM

PU-50563

Image for Reference Only

1/4” Drive Extension

Alignment Hole

SETTING TDC (TOP-DEAD-CENTER)

There ar e thre e ways to en sure the pisto n is at TDC. Remove the outer clutch cover to access the drive clutch to aid in engine ro tation (m anually turn the drive clutch counter clockwise).

1. With the CPS sensor removed, rotate the engine until “V” mar ked o n the flywhee l is a ligned with the

the CPS mounting ho le. This will se t TDC, but not

necessarily TDC o f t he compression st roke.

View the timing marks on the camshaft sprockets to ensure the e ngine is at TDC o f the co mpression stroke.

2. With t he v alve cover a nd thermostat h ousing

emoved, ro tate th e en gine so the cam lobe s a re

r facing ou tward a nd th e Cylin der Hold ing a nd Camshaft Timing Plate (PU-50563) can be installed into the slots of the camshafts as shown below. This will set TDC of the compression stroke.

IMPORTANT: Intake c am spr ocket shou ld h ave “I”

rks a ligned wit h g asket su rface and t he exhaust

ma cam s procket sh ould ha ve “E” mark s a ligned wit h gasket surface.

3. With the stator cover and flywh engine and position the piston at TDC by aligning the timing ho le in cra nk case with a timing hole in th e crankshaft. 



Insert a 1 /4” dr ive socket exte nsion through th e

ankcase and into the crankshaft locating hole. This

will s et TDC, but n ot necessarily TDC of the compression stroke. View the timing marks on the

cam shaft sprockets to ensure the engine is at TDC of the compression stroke.

eel removed, rotate the

3.36

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ENGINE / COOLING SYSTEM

Lobes should face out

ENGINE DISASSEMBLY / INSPECTION - TOP END

Valve Cover Removal

NOTE: The valve cover, camshafts, cy linder hea d, cylinder and piston can be serviced with the engine installed in the chassis.

1. If needed, rem ove th e sp ark plu g wir e fr om the ngine.

2. Remove dirt and debris from valve cover area.

3. Remove the ( 3) valve cover shoulder b olts (A) and

lators (B) using a T40 driver.

iso

4. Carefully lift valve cover from the engine and remove

it out of

the right-hand rear wheel well area.

Camshaft Removal

NOTE: The c amshafts c an be removed wit h the engine installed in the chassis.

1. Rotate the engine so the piston is at Top Dead Center on the compression stroke.

(TDC)

NOTE: To verify TD C, see the “S ETTING TDC” section in this chapter.

2. Remove the hydraulic cam chain tensioner (E) from

e cylin der. Repla ce the se aling washer (F ) u pon

th reassembly.

5. Replace isolators (B) and valve co ver seal (C) if oil aks are evident.

6. Remove the spark plug (D). Stuff spark plug hole with

shop towel to prevent anything from falling into the

a combustion chamber (if further engine disassembly is required).

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3.37

ENGINE / COOLING SYSTEM

G H

3. Remove the (2) bolts retaining th e fixed cam chain guide (G) and remove the assembly from the engine. Inspect the guide for wear and replace if necessary.

4. Remove th e re maining (6 ) b olts t hat r etain th e camshaft carrier (H) and carefully lift the carrier off the camshafts.

6. Mark the intake ( I) an d exha ust (J) camsh afts to e proper assembly.

ensur

7. Lift up ward on the intake ca mshaft wh ile r otating it

ounter-clockwise. Walk the timing chain off of th e

c sprocket. Carefully remove the intake camshaft from the engine.

8. Remove the cam chain fro m the exha ust ca mshaft

rocket (J) and remove the exhaust camshaft from

sp the engine.

NOTE: The crankcase has a lower guide t o prevent t

he chain from falling off the crankshaft.

5. Attach a hoo k or other tool to the camshaft chain to revent it from dropping down into the engine.

3.38

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ENGINE / COOLING SYSTEM

= T

Inspect

Sprocket Teeth

Replace if

Worn or Damaged

= In. / mm.

Camshaft Sprocket Inspection

NOTE: Camshaft sprocket removal is not necessary unless the replacement of the sprockets is required.

Inspect cam sprocket teeth for wear timing chain and sprockets as a set if worn or damaged.

IMPORTANT: Replace camshaft sprocket bolts if they

re loosened or removed.

or damage. Replace

Camshaft / Camshaft Bore Inspection

Inspect a ll main journals a nd cam lo bes as de scribed below and compare to specifications. Replace camshafts or cylinde r he ad if wo rn beyond s ervice limit or if any surface is pitted or damaged.

1. Visually inspect each cam lobe for wear or damage.

2. Measure the height of each cam lobe from the base cle to highest point on the lobe using a micrometer.

cir Compare to specification.

NOTE: Replace camshafts if damaged or if any part

worn past the service limit.

Camshaft Sprocket Bolts:

15 ft. lbs. (20 Nm)

Camshaft Lobe Height:

Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm)

Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm)

3. Visually insp ect each camsha ft journal for sco ring,

ar or damage.

4. Measure the diameter of the camshaft journals using

micrometer. Compare to specification.

3.39

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ENGINE / COOLING SYSTEM

= In. / mm.

= T

= In. / mm.

NOTE: Replace camshafts if damaged or if any part is worn past the service limit.

Camshaft Journal O.D. Standard:

0.9029” - 0.9037” (22.933 - 22.954 mm)

Service Limit:

0.9025” (22.923 mm)

5. Temporarily install the camshaft carriers to measure camsha ft b ore. To rque b olts in sequence to

the specification.

6. If the camshaft journal bo re is found to be ou t of ecification, re placement o f th e cylin der head

sp assembly is required.

NOTE: Replace cy linder he ad if camshaft jour nal

s are damaged or if worn past the service limit.

bore

Camshaft Journal Bore I.D. Standard:

0.9055" - 0.9063" (23.000 - 23.021 mm)

Camshaft Carrier Bolts:

7.5 ft. lbs. (10 Nm)

Service Limit: 0.9072" (23.044 mm)

7. Calculate o il cle arance b

journal O.D.s fro m camshaft car rier bor e I.D.s. Compare to specification.

Calculated Camshaft Oil Clearance:

0.0018" - 0.0034" (.046 - .088 mm)

Service Limit: .0047" (.121 mm)

y su btracting ca mshaft

3.40

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ENGINE / COOLING SYSTEM

Return Spring

Retaining Ring

Pivot

Decomp. Cam and Pin

= T

9 ft. lbs

(12 Nm)

Exhaust Camshaft Decompression Mechanism

NOTE: Removal of t he d ecompression mec hanism is not necessary unless replacement is required.

1. Thoroughly cle an an d inspe ct the de compression chanism located on the exhaust camshaft.

2. Replace th e decom pression assemb ly if any

cessive wear or binding is evident.

Cam Chain and Guide Service

NOTE: The cra nkcase has a remov able lowe r cam chain g uide t hat pre vents th e ch ain f rom disengaging the crankshaft during engine service.

NOTE: The c am c hain, ca m cha in guide s a nd c am

hain tensioner ca n b e re placed wit h t he eng ine

c installed in the vehicle.

1. If no t a lready pe rformed, re move th e va lve cov er, cover , flywhe el, cam chain tensioner, cam

stator carrier and camshafts as outlined in this chapter.

2. Remove the (2) fasteners that secure the cam chain

guides to

3. Remove the (2) fasteners that secure the lower cam

chain guide

4. Inspect all cam chain guides and replace if excessive

ar is evident.

5. Upon installation, torque all

and reassemble engine and vehicle as outlined in this chapter.

the crankcase.

to the crankcase.

fasteners to specification

3. Be sure th e de compression me chanism fu nctions thly and easily returns under spring pressure to

smoo the resting position against gravity.

Tension Blade and Guides:

9 ft. lbs. (12 Nm)

3.41

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ENGINE / COOLING SYSTEM

WARNING

PV-43513-A

Cylinder Head Removal

NOTE: The cy linder hea d ca n be se rviced with the engine installed in the chassis.

IMPORTANT: Do not rotate head assembly up side-

wn unt il the valve buck ets and shims hav e been

do removed.

1. Remove and discard the (2) outer M6 bolts (A) that etain the cylinder head (B) and the cylinder.

2. Loosen the (4) cylinder head bolts (C) evenly 1/8 turn 60 degrees) at a time until all are loose.

(

3. Remove an d d iscard the cylin der h ead bo lts ( C).

Replace with ne

4. Tap cyl inder he ad lightly with a so ft faced hammer

til loose. Tap only in reinforced areas or on thick

un parts of the cylinder head casting.

5. Remove the cylinder head (B) and head gasket (D).

w upon assembly.

Cylinder Head Disassembly

Wear eye protection during cylinder head

disassembly and reassembly or when working

with the valve springs.

IMPORTANT: Keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes. It is important to install cylinder head components b ack in the same lo cation. M ark each component or place them in an organized rack as you remove them.

1. Remove the valve bu cket ( F) an d a djustment shim G) from the cylinder head.

(

2. Compress the valve spring by hand using valve spring

mpressor adapter (PV-43513-A).

3.42

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ENGINE / COOLING SYSTEM

= In. / mm.

To p

Bottom

3. Push down on the spring and remove the split keepers (H).

9. Measure the free length of each valve spring with a Vernier caliper and compar

Valve Spring Free Length:

Standard: 1.7263" (43.85 mm)

Service Limit: 1.6830" (42.75 mm)

e to specification.

4. Slowly release valve spring pressure and remove the ressor adapter.

comp

5. Remove the valve retainer (I), valve spring (J), valve

stem se valve seal.

NOTE: Replace valve seals whenever cylinder head is disa will cause excessive oil consumption.

6. Lift up the cylinder head and push the valve (M) out,

ke guide.

7. Repeat the previous steps to re

valves.

8. Clean the co mbustion ch amber and he ad g asket

surf

al (K) an d valve spring seat (L). Discard the

ssembled. Harde ned, cr acked or worn s eals

eping it in order for reassembly in the same valve

move the remaining

ace.

3.43

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ENGINE / COOLING SYSTEM

CAUTION

= In. / mm.

Cylinder Head Inspection

Thoroughly clea n cylinde r h ead sur face to r emove a ll traces of gasket material and carbon.

Use care not to damage gasket sealing surface.

All gasket surfaces must be clean, dry and free

of any oil or grease upon assembly. Clean

sealing surfaces with rubbing alcohol or

electrical contact cleaner. Do not touch sealing

surfaces of the new head gasket.

Cylinder Head Warp Inspection

1. Lay a s traight ed ge ( E) ac ross the s urface of th e cylinder head at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.

Valve Inspection

1. Remove all carbon from valves with a soft wire wheel or brush.

2. Check va lve face for exce s burnt spots.

3. To chec k for bent v alve st em blocks and measure with a dial indicator.

sive runout, pit ting, a nd

s, mo unt va lve in “V ”

4. Check the end of the valve stem fo wear or damage.

Cylinder Head Warp Limit:

.0024" (0.06 mm)

5. Inspect split keeper groove for wear or flaring in the ke

eper seat area.

NOTE: The valves can be re-faced or end ground, if

essary. T hey mu st be re placed if e xtensively

nec worn, burnt, bent or damaged.

r flaring, pitti ng,

3.44

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ENGINE / COOLING SYSTEM

= In. / mm.

WARNING

Combustion Area

6. Measure diameter of valve stem with a micrometer in three places, then rotate 90° and measure again (take six measurements total). Compare to specifications.

Valve Stem Diameter:

Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm)

Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm)

Combustion Chamber Cleaning

Wear eye protection during combustion

chamber cleaning.

1. Clean a ll accumulated car bon dep osits fro m combustion chambers and valve seat area.

7. Measure valve guide inside dia and end of the guide using a small hole gauge and a micrometer. Measure in two directions.

Valve Guide I.D.:

0.2165" - 0.2171" (5.500 - 5.515 mm)

8. Be su re to mea sure each guide a nd valve combination indiv

idually.

meter at the top middle

NOTE: Carbon Clean Fu el Tre atment (2 871326) ca n

e used to help remove carbon deposits.

IMPORTANT: Do not u se a met al scr aper, a co arse

brush or abrasive cleaners to clean the cylinder

wire head. Damage may result.

2. Visually inspe ct cylinde r head g asket su rface and bustion chamber for cracks or damage. Pay close

com attention to th e ar eas a round sp ark p lug and valve seats.

NOTE: The valve guides cannot be replaced.

3.45

9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

WARNING

Valve Seat Reconditioning

Valve se at reconditioning should be pe rformed by a technician pr oficient in cylinder hea d reco nditioning techniques. Reconditioning techniques vary, so follow the instructions pr ovided by the valve reco nditioning equipment m anufacturer. D o not grind seats m ore than necessary t o provide p roper seat su rface, w idth, and contact point on valve face.

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots,

oughness, a nd u neven sur face. If a ny of the a bove

conditions exist, the valve seat must be reconditioned. If

the valve seat is cracked the cylinder head must be replaced.

Valve seat width and point of contact on the valve face is

y important for proper sealing. The valve must contact

ver the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too n arrow, he at tr ansfer fr om valve to seat is r educed. The valve may over heat an d warp , r esulting in burnt valves.

* If the contact area is less than 75% of the circumference

seat, rotate the pilot 180° and make another light cut.

of the

* If the cutter now contacts the uncut portion of the seat,

eck the pilot. Look for burrs, nicks, or runout. If the pilot

ch is bent it must be replaced.

* If the contact area of the cutter is in the valve guide is distorted from improper installation.

* If the contact area of the initial cut is greater than 75%, c

ontinue to cut the seat until all pits are removed and a new

seat surface is evident.

NOTE: Remove on ly t he a mount o f material

essary to repair the seat surface.

nec

5. To check the contact area of the seat on the valve ce, apply a thin coating of Prussian Blue paste to the

fa valve seat. If using an interference angle (46°) apply black p

6. Insert valve into guide and tap v

a few times.

ermanent marker to the entire valve face (A).

same place, the

alve lightly into place

Renewing Valve Seats

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

3. Place 46° cutter on the pilot and make a light cut.

4. Inspect the cut area of the seat:

3.46

7. Remove valve an d check where the Pru ssian Blu e

indicate seat should co ntact th e middle of th e valve face or slightly above, and must be the proper width.

* If the indicated seat contact is at the face and contacts the margin area (B) it is too high on the

valve face. Use the 30° cutter to lower the valve seat.

* If too lo w, use the 60° cutter to raise the se at. When co

ntact area is centered on the valve face, measure seat

width.

* If the seat is too wide or uneven, use both top and bottom

tters to narrow the seat.

* If the seat is too narrow, widen using the 45° cutter and

check contact point on the valve fa ce and seat width

reafter each cut.

9923523 - 2012 RANGER RZR 570 Service Manual

s seat contact o n the valve face . The valve

top edge of the valve

ENGINE / COOLING SYSTEM

Proper Seat Contact

on Valve Face

INTAKE

Seat Width

.039” (1.00 mm)

60°

45°

30°

= In. / mm.

EXHAUST

Seat Width

.059” (1.50 mm)

60°

45°

30°

NOTE: When us ing a n int erference a ngle, t he seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face (A).

Intake Seat Cutter Diameter: 1.567 in. (39.80 mm)

Exhaust Seat Cutter Diameter: 1.364 in. (34.65 mm)

Valve Seat Width:

Intake: .0393" (1.00 mm)

Service Limit: .0

Exhaust: .0

Service Limit: .0758" (1.9 mm)

8. Clean all filings from the area Rinse and dry with compressed air.

9. Lubricate valve guides with clean engine oil and apply

il or water based lapping compound to the face of the

o valve.

NOTE: Lapping is no t req uired if an interference

ngle reconditioning method is used.

10. Insert the valve into its respective guide and lap using

lapping tool or a section of fuel line connected to the

a valve stem.

11. Rotate th e valve rapidly back and forth until the cut

unds smooth. Lift the valve slightly off of the seat,

so rotate 1/4 turn, and repeat the lapping process. Do this four to f ive times until t he valve is fully seated, and repeat process for the other valves.

12. Thoroughly clean cylinder head and valves.

551" (1.4 mm)

590” (1.50 mm)

with hot s oapy water.

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9923523 - 2012 RANGER RZR 570 Service Manual

ENGINE / COOLING SYSTEM

1/2” Down From Top of Cylinder

1/2” Up From Bottom

Cylinder Removal

1. Remove and discard the head gasket.

2. Position the cam chain and guides vertically.

3. Tap cylin der lig htly with a p lastic h ammer in th e reinforced areas only

4. Rock cylinder forward and backward and lift it from the

ankcase, supporting piston and connecting rod.

5. Remove the cylinder from the engine.

until loose.

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing surfaces.

2. Inspect th e top of the cylin der for war page using a

ight edge and feeler gauge.

stra

Cylinder Warpage:

.00098” (.025 mm)

6. Remove and discard cylinder base gasket.

3. Inspect cylinder for wear, s

4. Inspect cylinder for ta per an d ou t o f r ound with a te

lescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on thr ee different levels (1 /2" down from top, in the middle, and 1/2” up from bottom).

cratches, or damage.

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9923523 - 2012 RANGER RZR 570 Service Manual

Polaris 2012 RANGER RZR 570 INTL, 2012 RANGER RZR 570 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual